Polyethylene copolymer compositions and their barrier properties

ABSTRACT

A dual reactor solution polymerization process gives high density polyethylene compositions containing a first ethylene copolymer and a second ethylene copolymer. The polyethylene compositions can be used in the manufacture of injection molded closures or cast film having good barrier properties.

TECHNICAL FIELD

The present disclosure relates to polyethylene compositions that are useful in the manufacture of films or molded articles having good barrier properties. Such articles include for example, cast film, or injection molded closures for bottles.

BACKGROUND ART

Work has been done to develop polyethylene compositions which comprise two ethylene homopolymer components where the components chosen are of relatively low and relatively high molecular weight. These ethylene homopolymer compositions, which may have a bimodal molecular weight distribution profile, have been usefully applied in the formation of films having good barrier properties (see for example U.S. Pat. Nos. 7,737,220 and 9,587,093, and U.S. Pat. Appl. Pub. Nos 2008/0118749, 2009/0029182 and 2011/0143155).

Conventional wisdom suggests that the barrier properties (e.g. gas or water vapor permeation rates) of a polyethylene having a given density should be superior for a polyethylene homopolymer composition relative to a polyethylene copolymer composition. Indeed, although polyethylene compositions comprising a first and a second ethylene copolymer of differing relative molecular weights and density have found application in molding applications such as closures (see for example U.S. Pat. Nos. 9,758,653; 9,074,082; 9,475,927; 9,783,663; 9,783,664; 8,962,755; 9,221,966; 9,371,442 and 8,022,143), less emphasis has so far been placed on the barrier properties of such resins (see for example WO 2016/135590).

SUMMARY OF INVENTION

We have now surprisingly found, that when polyethylene copolymer compositions are suitably designed, they can have barrier properties which approach those of comparable polyethylene homopolymer compositions. The new polyethylene copolymer compositions have good barrier properties when made into, for example, a compression molded film or an injection molded closure.

An embodiment of the disclosure is a polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂ ¹, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂₁/I₂, of less than 40; and a stress exponent of less than 1.40.

In an embodiment of the disclosure, the polyethylene copolymer composition further comprises a nucleating agent, or a mixture of nucleating agents.

In an embodiment of the disclosure, the polyethylene copolymer composition comprises a nucleating agent which is a salt of a dicarboxylic acid compound.

In an embodiment of the disclosure, the polyethylene copolymer composition comprises from 20 to 4000 ppm of a nucleating agent or a mixture of nucleating agents.

An embodiment of the disclosure is an injection molded article comprising the polyethylene copolymer composition.

An embodiment of the disclosure is a compression molded article comprising the polyethylene copolymer composition.

An embodiment of the disclosure is a closure (e.g. a closure for bottles) comprising the polyethylene copolymer composition.

An embodiment of the disclosure is a film comprising the polyethylene copolymer composition.

An embodiment of the disclosure is a cast film comprising the polyethylene copolymer composition.

An embodiment of the disclosure is a polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of from less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂ ¹, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂ ¹/I₂, of less than 40; and a stress exponent of less than 1.40; wherein the polyethylene copolymer composition is made by a process comprising contacting at least one single site polymerization catalyst system with ethylene under solution polymerization conditions in at least two polymerization reactors.

An embodiment of the disclosure is a process to prepare a polyethylene copolymer composition, the polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of from less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂ ¹, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂ ¹/I₂, of less than 40; and a stress exponent of less than 1.40; wherein the process comprises contacting at least one single site polymerization catalyst system with ethylene and at least one alpha-olefin under solution polymerization conditions in at least two polymerization reactors.

In an embodiment of the disclosure, the at least two polymerization reactors comprise a first reactor and a second reactor configured in series.

An embodiment of the disclosure is a polymer composition comprising from 1 to 100 percent by weight of a polyethylene copolymer composition, the polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, 121 of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂ ¹, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂ ¹/I₂, of less than 40; and a stress exponent of less than 1.40.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows the gel permeation chromatographs (GPC) with refractive index detection of polyethylene compositions (Examples 1-3) made according to the present disclosure.

FIG. 2 shows the oxygen transmission rates (OTR) of compression molded films made from nucleated polyethylene compositions (Examples 1*-3*) according to the present disclosure vs. the density of the nucleated polyethylene compositions (Examples 1*-3*). FIG. 2 also shows the oxygen transmission rates (OTR) of compression molded films made from comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8) vs. the density of the comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8).

FIG. 3 shows the water vapor transmission rates (WVTR) of compression molded films made from nucleated polyethylene compositions (Examples 1*-3*) according to the present disclosure vs. the density of the nucleated polyethylene compositions (Examples 1*-3*). FIG. 3 also shows the water vapor transmission rates (WVTR) of compression molded films made from comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8) vs. the density of the comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8).

FIG. 4 shows the oxygen transmission rates (OTR) of injection molded closures made from nucleated polyethylene compositions (Examples 1*-3*) according to the present disclosure vs. the density of the nucleated polyethylene compositions (Examples 1*-3*). FIG. 4 also shows the oxygen transmission rates (OTR) of injection molded closures made from comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8) vs. the density of the comparative nucleated polyethylene compositions (Examples 4*, 5*, 6* as well as 7 and 8).

DESCRIPTION OF EMBODIMENTS

By the terms “ethylene homopolymer” or “polyethylene homopolymer”, or “ethylene homopolymer composition” it is meant that the polymer referred to is the product of a polymerization process, where only ethylene was deliberately added as a polymerizable olefin. In contrast, the terms “ethylene copolymer” or “polyethylene copolymer”, or “polyethylene copolymer composition” mean that the polymer referred to is the product of a polymerization process, where ethylene and one or more than one alpha olefin comonomer were deliberately added as polymerizable olefins.

The term “unimodal” is herein defined to mean there will be only one significant peak or maximum evident in a GPC-curve. A unimodal profile includes a broad unimodal profile. Alternatively, the term “unimodal” connotes the presence of a single maxima in a molecular weight distribution curve generated according to the method of ASTM D6474-99. In contrast, by the term “bimodal” it is meant that there will be a secondary peak or shoulder evident in a GPC-curve which represents a higher or lower molecular weight component (i.e. the molecular weight distribution, can be said to have two maxima in a molecular weight distribution curve). Alternatively, the term “bimodal” connotes the presence of two maxima in a molecular weight distribution curve generated according to the method of ASTM D6474-99. The term “multi-modal” denotes the presence of two or more maxima in a molecular weight distribution curve generated according to the method of ASTM D6474-99.

In an embodiment of the disclosure a polymer composition comprises from 1 to 100 percent by weight of a polyethylene copolymer composition as defined herein.

In an embodiment of the disclosure, a polyethylene copolymer composition comprises two components, (1) a first ethylene copolymer and (2) a second ethylene copolymer which is different from the first ethylene copolymer.

In an embodiment of the disclosure, a polyethylene copolymer composition comprises only two polymer components, (1) a first ethylene copolymer and (2) a second ethylene copolymer which is different from the first ethylene copolymer.

In an embodiment of the disclosure, a polyethylene copolymer composition further comprises a nucleating agent.

The first and second ethylene copolymers are defined further below.

The First Ethylene Copolymer

In an embodiment of the disclosure the first ethylene copolymer comprises both polymerized ethylene and at least one polymerized alpha-olefin comonomer, with polymerized ethylene being the majority species.

In an embodiment of the disclosure the first ethylene copolymer is made using a single site polymerization catalyst.

In an embodiment of the disclosure the first ethylene copolymer is made using a single site polymerization catalyst in a solution phase polymerization process.

In an embodiment of the disclosure, the comonomer (i.e., alpha-olefin) content in the first ethylene copolymer can be from about 0.05 to about 3.0 mol % as measured by ¹³C NMR, or FTIR or GPC-FTIR methods, or as calculated from a reactor model (see the Examples section). The comonomer is one or more suitable alpha olefin, which include, but are not limited to, 1-butene, 1-hexene, 1-octene and the like. In one embodiment the alpha olefin is 1-octene.

In an embodiment of the disclosure, the short chain branching in the first ethylene copolymer can be from about 0.10 to about 15 short chain branches per thousand carbon atoms (SCB1/1000Cs). In further embodiments of the disclosure, the short chain branching in the first ethylene copolymer can be from 0.10 to 10, or from 0.20 to 10, or from 0.20 to 5, or from 0.20 to 3, or from 0.10 to 5, or from 0.10 to 1, or from 0.20 to 1 branches per thousand carbon atoms (SCB1/1000Cs). The short chain branching is the branching due to the presence of alpha-olefin comonomer in the ethylene copolymer and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc. The comonomer is one or more suitable alpha-olefin, which include, but are not limited to, 1-butene, 1-hexene, 1-octene and the like. In one embodiment the alpha olefin is 1-octene.

In embodiments of the disclosure, the comonomer in the first ethylene copolymer is one or more olefin such as but not limited to 1-butene, 1-hexene, 1-octene and the like.

In an embodiment of the disclosure, the first ethylene copolymer is a copolymer of ethylene and 1-octene.

In an embodiment of the disclosure, the comonomer content in the first ethylene copolymer is greater than comonomer content of the second ethylene copolymer (as reported, for example, in mol %).

In an embodiment of the disclosure, the amount of short chain branching in the first ethylene copolymer is greater than the amount of short chain branching in the second ethylene copolymer (as reported in short chain branches, SCB per thousand carbons in the polymer backbone, 1000Cs).

In an embodiment of the disclosure, the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer.

In embodiments of the disclosure the first ethylene copolymer has a melt index, I₂ ¹ of ≤25.0 g/10 min, or ≤15.0 g/10 min, or ≤10.0 g/10 min, or ≤5.0 g/10 min. In another embodiment of the disclosure, the first ethylene copolymer has a melt index, I₂ ¹ of from 0.001 to less than 25.0 g/10 min, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the melt index, I₂ ¹ of the first ethylene copolymer may be from 0.001 to 20.0 g/10 min, or from 0.001 to 15.0 g/10 min, or from 0.001 to 10.0 g/10 min, or 0.001 to 5.0 g/10 min, or from 0.01 to 25.0 g/10 min, or from 0.01 to 20.0 g/10 min, or from 0.01 to 15.0 g/10 min, or from 0.01 to 10.0 g/10 min, or from 0.01 to 5.0 g/10 min, or from 0.1 to 25.0 g/10 min, or from 0.1 to 20.0 g/10 min, or from 0.1 to 15.0 g/10 min, or from 0.1 to 10.0 g/10 min, or from 0.1 to 5.0 g/10 min.

In an embodiment of the disclosure, the first ethylene copolymer has a melt flow ratio, I₂ ¹/I₂ of less than 25, or less than 23, or less than 20.

In an embodiment of the disclosure, the first ethylene copolymer has a weight average molecular weight, M_(w) of from 40,000 to 250,000 g/mol, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the first ethylene copolymer has a weight average molecular weight, M_(w) of from 50,000 to 200,000 g/mol, or from 50,000 to 175,000 g/mol, or from 50,000 to 150,000 g/mol, or from 40,000 to 125,000 g/mol, or from 50,000 to 135,000 g/mol.

In embodiments of the disclosure, the first ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of ≤3.0, or <3.0, or ≤2.7, or <2.7, or ≤2.5, or <2.5, or ≤2.3, or <2.3, or ≤2.1, or <2.1 or about 2. In another embodiment of the disclosure, the first ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of from 1.7 to 3.0, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the first ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of from 1.8 to 2.7, or from 1.8 to 2.5, or from 1.8 to 2.3, or from 1.9 to 2.1.

In an embodiment of the disclosure, the density, d¹ of the first copolymer is less than the density, d² of the second ethylene copolymer.

In an embodiment of the disclosure, the first ethylene copolymer has a density, d¹ of from 0.920 to 0.985 g/cm³, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the first ethylene copolymer has a density, d¹ of from 0.925 to 0.980 g/cm³, or from 0.927 to 0.975 g/cm³, or from 0.930 to 0.980 g/cm³, or from 0.935 to 0.980 g/cm³, or from 0.937 to 0.980 g/cm³, or from 0.940 to 0.980 g/cm³, or from 0.940 to 0.975 g/cm³, or from 0.937 to 0.975 g/cm³, or from 0.935 to 0.975 g/cm³, or from 0.933 to 0.975 g/cm³, or from 0.930 to 0.975 g/cm³, or from 0.935 to 0.970 g/cm³, or from 0.940 to 0.965 g/cm³, or from 0.935 to 0.965 g/cm³, or from 0.933 to 0.965 g/cm³, or from 0.930 to 0.965 g/cm³, or from 0.940 to 0.960 g/cm³, or from 0.937 to 0.960 g/cm³, or from 0.935 to 0.960 g/cm³, or from 0.933 to 0.960 g/cm³, or from 0.931 to 0.960 g/cm³, or from 0.930 to 0.960 g/cm³, or from 0.940 to 0.957 g/cm³, or from 0.937 to 0.957 g/cm³, or from 0.935 to 0.957 g/cm³, or from 0.933 to 0.957 g/cm³, or from 0.931 to 0.957 g/cm³, or from 0.930 to 0.957 g/cm³, or from 0.936 to 0.955 g/cm³, or from 0.936 to 0.952 g/cm³.

In an embodiment of the disclosure, a single site catalyst which gives an ethylene copolymer having a CDBI(50) of at least 65% by weight, or at least 70%, or at least 75%, or at least 80%, or at least 85%, during solution phase polymerization in a single reactor, is used in the preparation of the first ethylene copolymer.

In an embodiment of the present disclosure, the first ethylene copolymer is ethylene copolymer which has a CDBI(50) of greater than about 60% by weight, or greater than about 65%, or greater than about 70%, or greater than about 75%, or greater than about 80%, or greater than about 85%.

In embodiments of the disclosure, the weight percent (wt %) of the first ethylene copolymer in the polyethylene copolymer composition (i.e. the weight percent of the first ethylene copolymer based on the total weight of the first and second ethylene copolymers) may be from about 5 wt % to about 95 wt %, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the weight percent (wt %) of the first ethylene copolymer in the polyethylene copolymer composition may be from about 5 wt % to about 90 wt %, or from about 10 wt % to about 90 wt %, or from about 5 wt % to about 80 wt %, or from about 10 wt % to about 70 wt %, or from about 5 wt % to about 70 wt %, or from about 5 wt % to about 60 wt %, or from about 10 wt % to about 50 wt %, or from about 15 wt % to about 45 wt %, or from about 20 wt % to about 40 wt %, or from about 20 wt % to about 50 wt %, or from about 20 wt % to about 55 wt %.

The Second Ethylene Copolymer

In an embodiment of the disclosure the second ethylene copolymer comprises both polymerized ethylene and at least one polymerized alpha-olefin comonomer, with polymerized ethylene being the majority species.

In an embodiment of the disclosure the second ethylene copolymer is made using a single site polymerization catalyst.

In an embodiment of the disclosure the second ethylene copolymer is made using a single site polymerization catalyst in a solution phase polymerization process.

In an embodiment of the disclosure, the comonomer content in the second ethylene copolymer can be from about 0.03 to about 3 mol % as measured by ¹³C NMR, or FTIR or GPC-FTIR methods, or as calculated from a reactor model (see Examples section). The comonomer is one or more suitable alpha olefins, which include, but are not limited to, 1-butene, 1-hexene, 1-octene and the like. In one embodiment the alpha olefin is 1-octene.

In an embodiment of the disclosure, the short chain branching in the second ethylene copolymer can be from about 0.05 to about 10 short chain branches per thousand carbon atoms (SCB1/1000Cs). In further embodiments of the disclosure, the short chain branching in the second ethylene copolymer can be from 0.05 to 7.5, or from 0.05 to 5, or from 0.05 to 3, or from 0.05 to 1 branches per thousand carbon atoms (SCB1/1000Cs). The short chain branching is the branching due to the presence of alpha-olefin comonomer in the ethylene copolymer and will for example have two carbon atoms for a 1-butene comonomer, or four carbon atoms for a 1-hexene comonomer, or six carbon atoms for a 1-octene comonomer, etc. The comonomer is one or more suitable alpha olefin. Examples of alpha olefins include, but are not limited to 1-butene, 1-hexene, 1-octene and the like. In one embodiment the alpha olefin is 1-octene.

In embodiments of the disclosure, the comonomer in the second ethylene copolymer is one or more olefin such as but not limited to 1-butene, 1-hexene, 1-octene and the like.

In an embodiment of the disclosure, the second ethylene copolymer is a copolymer of ethylene and 1-octene.

In an embodiment of the disclosure, the comonomer content in the second ethylene copolymer is less than the comonomer content of the first ethylene copolymer (as reported for example in mol %).

In an embodiment of the disclosure, the amount of short chain branching in the second ethylene copolymer is less than the amount of short chain branching in the first ethylene copolymer (as reported in short chain branches, SCB per thousand carbons in the polymer backbone, 1000Cs).

In an embodiment of the disclosure, the melt index, I₂ ² of the second ethylene copolymer is greater than the melt index, I₂ ¹ of first ethylene copolymer.

In an embodiment of the disclosure, the ratio of the melt index, I₂ ² of the second ethylene copolymer to the melt index, I₂ ¹ of the first ethylene copolymer is from 1.1 to 500, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the ratio of the melt index, I₂ ² of the second ethylene copolymer to the melt index, 121 of the first ethylene copolymer may be from 1.1 to 250, or from 1.1 to 100, or from 1.1 to 75.

In embodiments of the disclosure the second ethylene copolymer has a melt index, I₂ ² of <50.0 g/10 min, or ≤45.0 g/10 min, or ≤43.0 g/10 min. In another embodiment of the disclosure, the second ethylene copolymer has a melt index, I₂ ² of from 0.1 to less than 50.0 g/10 min, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the melt index, I₂ ² of the second ethylene copolymer may be from 0.1 to 49.5 g/10 min, or from 0.1 to 45.0 g/10 min, or from 1 to less than 50 g/10 min, or from 1 to 49.5 g/10 min, or from 1 to 45.0 g/10 min, or from 5 to less than 50 g/10 min, or from 5 to 49.5 g/10 min, or from 5 to 45.0 g/10 min, or from 10 to less than 50 g/10 min, or from 10 to 49.5 g/10 min, or from 10 to 45.0 g/10 min, or from 20 to less than 50 g/10 min, or from 20 to 49.5 g/10 min, or from 20 to 45.0 g/10 min, or from 30 to less than 50 g/10 min, or from 30 to 49.5 g/10 min, or from 30 to 45.0 g/10 min, or from 35 to less than 50 g/10 min, or from 35 to 49.5 g/10 min, or from 35 to 45.0 g/10 min.

In an embodiment of the disclosure, the second ethylene copolymer has a melt flow ratio, I₂ ¹/I₂ of less than 25, or less than 23, or less than 20.

In an embodiment of the disclosure, the second ethylene copolymer has a weight average molecular weight, M_(w) of ≤75,000 g/mol, or ≤60,000 g/mol, or ≤50,000 g/mol, or ≤45,000 g/mol, or ≤40,000 g/mol. In another embodiment the second ethylene copolymer has a weight average molecular weight, M_(w) of from 5,000 to 100,000 g/mol, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the second ethylene copolymer has a weight average molecular weight, M_(w) of from 10,000 to 75,000 g/mol, or from 15,000 to 65,000 g/mol, or from 20,000 to 60,000 g/mol, or from 20,000 to 55,000 g/mol, or from 20,00 to 50,000 g/mol.

In embodiments of the disclosure, the second ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of ≤3.0, or <3.0, or ≤2.7, or <2.7, or ≤2.5, or <2.5, or ≤2.3, or <2.3, or ≤2.1, or <2.1 or about 2. In another embodiment of the disclosure, the second ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of from 1.7 to 3.0, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the second ethylene copolymer has a molecular weight distribution, M_(w)/M_(n) of from 1.8 to 2.7, or from 1.8 to 2.5, or from 1.8 to 2.3, or from 1.9 to 2.1.

In an embodiment of the disclosure, the density, d² of the second copolymer is greater than the density, d¹ of the first ethylene copolymer.

In an embodiment of the disclosure, the density, d² of the second ethylene copolymer is less than 0.031 g/cm³ greater than the density, d¹ of the first ethylene copolymer. In an embodiment of the disclosure, the density, d² of the second ethylene copolymer is less than 0.025 g/cm³ greater than the density, d¹ of the first ethylene copolymer. In an embodiment of the disclosure, the density, d² of the second ethylene copolymer is less than 0.020 g/cm³ greater than the density, d¹ of the first ethylene copolymer. In an embodiment of the disclosure, the density, d² of the second ethylene copolymer is less than 0.0175 g/cm³ greater than the density, d¹ of the first ethylene copolymer.

In an embodiment of the disclosure, the second ethylene copolymer has a density, d² of less than 0.970 g/cm³, or less than 0.967 g/cm³, or less than 0.965 g/cm³, or less than 0.963 g/cm³, or less than 0.961 g/cm³.

In an embodiment of the disclosure, the second ethylene copolymer has a density, d² of from 0.943 to 0.985 g/cm³, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the second ethylene copolymer has a density, d² of from 0.945 to 0.985 g/cm³, or from 0.947 to 0.985 g/cm³, or from 0.950 to 0.985 g/cm³, or from 0.943 to 0.980 g/cm³, or from 0.945 to 0.980 g/cm³, or from 0.947 to 0.980 g/cm³, or from 0.950 to 0.980 g/cm³, or from 0.951 to 0.985 g/cm³, or from 0.951 to 0.985 g/cm³, or from 0.951 to 0.980 g/cm³, or from 0.943 to 0.975 g/cm³, or from 0.945 to 0.975 g/cm³, or from 0.947 to 0.975 g/cm³, or from 0.950 to 0.975 g/cm³, or from 0.950 to 0.970 g/cm³, or from 0.945 to 0.965 g/cm³, or from 0.947 to 0.965 g/cm³.

In an embodiment of the disclosure, a single site catalyst which gives an ethylene copolymer having a CDBI(50) of at least 65% by weight, or at least 70%, or at least 75%, or at least 80%, or at least 85%, during solution phase polymerization in a single reactor, is used in the preparation of the second ethylene copolymer.

In an embodiment of the present disclosure, the second ethylene copolymer is ethylene copolymer which has a CDBI(50) of greater than about 60% by weight, or greater than about 65%, or greater than about 70%, or greater than about 75%, or greater than about 80%, or greater than about 85%.

In embodiments of the disclosure, the weight percent (wt %) of the second ethylene copolymer in the polyethylene copolymer composition (i.e. the weight percent of the second ethylene copolymer based on the total weight of the first and second ethylene copolymers) may be from about 95 wt % to about 5 wt %, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the weight percent (wt %) of the second ethylene copolymer in the polyethylene copolymer composition may be from about 90 wt % to about 10 wt %, or from about 90 wt % to about 20 wt %, or from about 90 wt % to about 30 wt %, or from about 90 wt % to about 40 wt %, or from about 90 wt % to about 50 wt %, or from about 80 wt % to about 50 wt %, or from about 80 wt % to about 60 wt %, or from about 80 wt % to about 45 wt %.

The Polyethylene Copolymer Composition

In an embodiment of the disclosure, the polyethylene copolymer composition will comprise a first ethylene copolymer and a second ethylene copolymer (each as defined herein).

In an embodiment of the disclosure, the polyethylene copolymer composition has a unimodal profile (i.e. a unimodal molecular weight distribution) in a gel permeation chromatography (GPC) analysis.

In an embodiment of the disclosure, the polyethylene copolymer composition has a unimodal profile in a gel permeation chromatograph generated according to the method of ASTM D6474-99.

In an embodiment of the disclosure, the polyethylene copolymer composition that comprises a first ethylene copolymer and a second ethylene copolymer (as defined above) will have a ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (i.e., SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (i.e., SCB2) of greater than 1.0 (i.e., SCB1/SCB2>1.0). In further embodiments of the disclosure, the ratio of the short chain branching in the first ethylene copolymer (SCB1) to the short chain branching in the second ethylene copolymer (SCB2) is at least 1.5. In still another embodiment of the disclosure, the ratio of the short chain branching in the first ethylene copolymer (SCB1) to the short chain branching in the second ethylene copolymer (SCB2) is at least 2.0. In still another embodiment of the disclosure, the ratio of the short chain branching in the first ethylene copolymer (SCB1) to the short chain branching in the second ethylene copolymer (SCB2) is greater than 2.0. In still another embodiment of the disclosure, the ratio of the short chain branching in the first ethylene copolymer (SCB1) to the short chain branching in the second ethylene copolymer (SCB2) is at least 2.5. In embodiments of the disclosure, the ratio (SCB1/SCB2) of the short chain branching in the first ethylene copolymer (SCB1) to the short chain branching in the second ethylene copolymer (SCB2) will be from greater than 1.0 to about 12.0, or from greater than 1.0 to about 10, or from greater than 1.0 to about 7.0, or from greater than 1.0 to about 5.0, or from about 2.0 to about 10.0, or from about 2.0 to about 7.5, or from about 2.0 to about 5.0.

In an embodiment of the disclosure, the polyethylene copolymer composition has a weight average molecular weight, M_(w) of ≤100,000 g/mol, or ≤75,000 g/mol, or <70,000 g/mol, or ≤65,000 g/mol, or <65,000 g/mol or ≤60,000 g/mol, or <60,000 g/mol. In another embodiment, the polyethylene copolymer composition has a weight average molecular weight, M_(w) of from 20,000 to 125,000 g/mol, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a weight average molecular weight, M_(w) of from 25,000 to 100,000 g/mol, or from 25,000 to 90,000 g/mol, or from 30,000 to 80,000 g/mol, or from 30,000 to 75,000 g/mol, or from 35,000 to 65,000 g/mol, or from 35,000 to 60,000 g/mol.

In an embodiment of the disclosure, the polyethylene copolymer composition has a number average molecular weight, M_(n) of ≤60,000 g/mol, or ≤50,000 g/mol, or <50,000 g/mol, or ≤45,000 g/mol, or <45,000 g/mol, or ≤40,000 g/mol, or <40,000 g/mol, or ≤35,000 g/mol, or <35,000 g/mol, or ≤30,000 g/mol, or <30,000 g/mol. In another embodiment of the disclosure, the polyethylene copolymer composition has a number average molecular weight, M_(n) of from 5,000 to 60,000 g/mol, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a number average molecular weight, M_(n) of from 10,000 to 55,000 g/mol, or from 10,000 to 50,000 g/mol, or from 15,000 to 50,000 g/mol, or from 15,000 to 45,000 g/mol, or from 15,000 to 40,000 g/mol, or from 15,000 to 35,000 g/mol, or from 15,000 to 30,000 g/mol, or from 20,000 to 50,000 g/mol, or from 20,000 to 45,000 g/mol, or from 20,000 to 40,000 g/mol, or from 20,000 to 35,000 g/mol, or from 20,000 to 30,000 g/mol.

In an embodiment of the disclosure, the polyethylene copolymer composition has a Z-average molecular weight, M_(z), of below about 200,000 g/mol. In another embodiment of the disclosure, the polyethylene copolymer composition has a Z-average molecular weight, M_(z), of below about 175,000 g/mol. In yet another embodiment of the disclosure, the polyethylene copolymer composition has a Z-average molecular weight, M_(z), of below about 150,000 g/mol. In yet another embodiment of the disclosure, the polyethylene copolymer composition has a Z-average molecular weight, M_(z), of below about 125,000 g/mol.

In embodiments of the disclosure, the polyethylene copolymer composition has a molecular weight distribution, M_(w)/M_(n) of ≤7.0, or <7.0, or ≤6.5, or <6.5, or ≤6.0, or <6.0, or ≤5.5, or <5.5, or ≤5.0, or <5.0, or ≤4.5, or <4.5, or ≤4.0, or <4.0, or ≤3.5, or <3.5, or ≤3.0, or <3.0, or ≤2.5, or <2.5. In another embodiment of the disclosure, the polyethylene copolymer composition has a molecular weight distribution, M_(w)/M_(n) of from 1.7 to 7.0, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a molecular weight distribution, M_(w)/M_(n) of from 1.8 to 7.0, or from 1.8 to 6.5, or from 1.8 to 6.0, or from 1.8 to 5.5, or from 1.8 to 5.0, or from 1.8 to 4.5, or from 1.8 to 4.0, or from 1.8 to 3.5, or from 1.8 to 3.0, or from 1.8 to 2.5, or from 2.0 to 5.0, or from 2.0 to 4.5, or from 2.0 to 4.0, or from 2.0 to 3.5, or from 2.0 to 3.0, or from 2.0 to 2.5.

In embodiments of the disclosure, the polyethylene copolymer composition has a density of 0.949 g/cm³, or >0.949 g/cm³, or ≥0.950 g/cm³, or >0.950 g/cm³, or ≥0.953 g/cm³, or >0.953 g/cm³, or ≥0.955 g/cm³, or >0.955 g/cm³.

In an embodiment of the disclosure, the polyethylene copolymer composition has a density of from 0.943 to 0.987 g/cm³, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a density of from 0.945 to 0.985 g/cm³, or from 0.947 to 0.985 g/cm³, or from 0.950 to 0.985 g/cm³, or from 0.953 to 0.985 g/cm³, or from 0.955 to 0.985 g/cm³, or from 0.945 to 0.980 g/cm³, or from 0.947 to 0.980 g/cm³, or from 0.950 to 0.980 g/cm³, or from 0.951 to 0.980 g/cm³, or from 0.953 to 0.980 g/cm³, or from 0.955 to 0.980 g/cm³, or from 0.945 to 0.975 g/cm³, or from 0.947 to 0.975 g/cm³, or from 0.950 to 0.975 g/cm³, or from 0.951 to 0.975 g/cm³, or from 0.953 to 0.975 g/cm³, or from 0.955 to 0.975 g/cm³, or from 0.945 to 0.970 g/cm³, or from 0.947 to 0.970 g/cm³, or from 0.950 to 0.970 g/cm³, or from 0.951 to 0.970 g/cm³, or from 0.953 to 0.970 g/cm³, or from 0.955 to 0.970 g/cm³, or from 0.945 to 0.965 g/cm³, or from 0.947 to 0.965 g/cm³, or from 0.950 to 0.965 g/cm³, or from 0.951 to 0.965 g/cm³, or from 0.953 to 0.965 g/cm³, or from 0.955 to 0.965 g/cm³, or from 0.945 to 0.960 g/cm³, or from 0.947 to 0.960 g/cm³, or from 0.950 to 0.960 g/cm³, or from 0.951 to 0.960 g/cm³, or from 0.953 to 0.960 g/cm³, or from 0.955 to 0.960 g/cm³.

In embodiments of the disclosure the polyethylene copolymer composition has a melt index, I₂ of at least 1.0 g/10 min (1.0 g/10 min), or at least 3.0 g/10 min (3.0 g/10 min), or at least 5.0 g/10 min (5.0 g/10 min), or at least 7.5 g/10 min (7.5 g/10 min), or at least 10 g/10 min (10.0 g/10 min), or greater than 3.0 g/10 min (>3.0 g/10 min), or greater than 5.0 g/10 min (>5.0 g/10 min), or greater than 7.5 g/10 min (>7.5 g/10 min), or greater than 10.0 g/10 min (>10.0 g/10 min). In another embodiment of the disclosure, the polyethylene copolymer composition has a melt index, I₂ of from 1.0 to 250 g/10 min, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the melt index, I₂ of the polyethylene copolymer composition may be from 1.0 to 200 g/10 min, or from 1.0 to 150 g/10 min, or from 1 to 100 g/10 min, or from 1 to 50 g/10 min, or from 10.0 to 200 g/10 min, or from 10.0 to 150 g/10 min, or from 10.0 to 100 g/10 min, or from 10.0 to 50 g/10 min, or from 7.5 to 200 g/10 min, or from 7.5 to 150 g/10 min, or from 7.5 to 100 g/10 min, or from 7.5 to 50 g/10 min, or from 5.0 to 200 g/10 min, or from 5.0 to 150 g/10 min, or from 5.0 to 100 g/10 min, or from 5.0 to 75 g/10 min, or from 5.0 to 50 g/10 min, or from 5.0 to 40 g/10 min, or from 3.0 to 100 g/10 min, or from 3.0 to 75 g/10 min, or from 3.0 to 50 g/10 min, or from 3.0 to 40 g/10 min.

In embodiments of the disclosure the polyethylene copolymer composition has a high load melt index, I₂₁ of at least 150 g/10 min (150 g/10 min), or at least 175 g/10 min (175 g/10 min), or at least 200 g/10 min (200 g/10 min), or greater than 200 g/10 min (>200 g/10 min), or at least 225 g/10 min (225 g/10 min), or greater than 225 g/10 min (>225 g/10 min), or at least 250 g/10 min (250 g/10 min), or greater than 250 g/10 min (>250 g/10 min). In another embodiment of the disclosure, the polyethylene copolymer composition has a high load melt index, I₂₁ of from 175 to 1200 g/10 min, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the high load melt index, I₂₁ of the polyethylene copolymer composition may be from 175 to 1000 g/10 min, or from 175 to 750 g/10 min, from 200 to 1000 g/10 min, or from 200 to 750 g/10 min, or from 225 to 1000 g/10 min, or from 225 to 750 g/10 min, or from 250 to 1000 g/10 min, or from 250 to 750 g/10 min.

In embodiments of the disclosure the polyethylene copolymer composition has a melt flow ratio, I₂₁/I₂ of ≤50, or <50, or ≤45, or <40, or ≤35, or <35, or ≤30, or <30, or ≤25, or <25. In another embodiment of the disclosure, the polyethylene copolymer composition has a melt flow ratio, I₂₁/I₂ of from 12 to 50, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a melt flow ratio, I₂₁/I₂ of from 14 to 45, or from 14 to 42, or from 16 to 40, or from 16 to 38, or from 16 to 36, or from 16 to 34, or from 16 to 32, or from 14 to 30, or from 14 to 28.

In an embodiment of the disclosure, the polyethylene copolymer composition has a stress exponent, defined as Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16], which is ≤1.40, or <1.40. In further embodiments of the disclosure the polyethylene copolymer composition has a stress exponent, Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16] of less than 1.38, or less than 1.36, or less than 1.34, or less than 1.32, or less than 1.30, or less than 1.28.

In an embodiment of the disclosure, the polyethylene copolymer composition has a shear viscosity at about 10⁵ s⁻¹ (240° C.) of less than about 10 Pa·s. In an embodiment of the disclosure, the polyethylene copolymer composition has a shear viscosity at about 10⁵ s⁻¹ (240° C.) of from about 3 to about 12 Pa·s including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the polyethylene copolymer composition has a shear viscosity at about 10⁵ s⁻¹ (240° C.) of from about 5 to about 12 Pa·s, or from about 6 to about 12 Pa·s, or from about 6 to about 10 Pa·s.

In an embodiment of the invention, the shear viscosity ratio, SVR(_(100,100000)) at 240° C. of the polyethylene copolymer composition can be from about 5 to about 70, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, the shear viscosity ratio, SVR(_(100,100000)) at 240° C. of the polyethylene copolymer composition can be from about 10 to about 60, or from about 10 to about 50, or from about 5 to about 50, or from about 10 to about 55, or from about 10 to about 45, or from about 5 to about 45.

In embodiments of the disclosure, the polyethylene copolymer composition has a hexane extractable value of ≤5.5 weight percent, or less than 4.5 wt %, or less than 3.5 wt %, or less than 2.5 wt %, or less than 2.0 wt %, or less than 1.5 wt %, or less than 1.0 wt %, or less than 0.5 wt %.

In an embodiment of the disclosure, the polyethylene copolymer composition has a composition distribution breadth index (CDBI(50)), as determined by temperature elution fractionation (TREF), of ≥about 60 weight percent. In further embodiments of the disclosure, the polyethylene composition will have a CDBI(50) of greater than about 65%, or greater than about 70%, or greater than about 75%, or greater than about 80%, or greater than about 85%.

In an embodiment of the disclosure, the polyethylene copolymer composition has a composition distribution breadth index (CDBI(25)), as determined by temperature elution fractionation (TREF), of ≥about 55 weight percent. In further embodiments of the disclosure, the polyethylene composition will have a CDBI(25) of greater than about 60%, or greater than about 65%, or from about 55 to about 75%, or from about 60 to about 75%.

In embodiments of the disclosure, the polyethylene copolymer composition or a molded article (or plaque) made from the polyethylene copolymer composition, has an environment stress crack resistance ESCR Condition B at 10% of fewer than 50 hours, or fewer than 40 hours, or fewer than 30 hours, or fewer than 20 hours as measured according to ASTM D1693 (at 10% IGEPAL® and 50° C. under condition B).

In embodiments of the disclosure, the polyethylene copolymer composition or a molded article (or plaque) made from the polyethylene copolymer composition, has an environment stress crack resistance ESCR Condition B at 100% of fewer than 10 hours, or fewer than 5 hours, or fewer than 3.5 hours as measured according to ASTM D1693 (at 100% IGEPAL and 50° C. under condition B).

The polyethylene copolymer composition of this disclosure can be made using any conventional blending method such as but not limited to physical blending and in-situ blending by polymerization in multi reactor systems. For example, it is possible to perform the mixing of the first ethylene copolymer with the second ethylene copolymer by molten mixing of the two preformed polymers. Preferred are processes in which the first and second ethylene copolymers are prepared in at least two sequential polymerization stages, however, both in-series or an in-parallel dual reactor process are contemplated for use in the current disclosure. Gas phase, slurry phase or solution phase reactor systems may be used, with solution phase reactor systems being preferred.

Mixed catalyst single reactor systems may also be employed to make the polyethylene copolymer compositions of the present disclosure.

In an embodiment of the current disclosure, a dual reactor solution polymerization process is used as has been described in for example U.S. Pat. No. 6,372,864 and U.S. Pat. Appl. No. 20060247373A1 which are incorporated herein by reference.

Generally, the catalysts used in the current disclosure will be so called single site catalysts based on a group 4 metal having at least one cyclopentadienyl ligand. Examples of such catalysts which include metallocenes, constrained geometry catalysts and phosphinimine catalysts are typically used in combination with activators selected from methylaluminoxanes, boranes or ionic borate salts and are further described in U.S. Pat. Nos. 3,645,992; 5,324,800; 5,064,802; 5,055,438; 6,689,847; 6,114,481 and 6,063,879. Such single site catalysts are distinguished from traditional Ziegler-Natta or Phillips catalysts which are also well known in the art. In general, single site catalysts produce ethylene copolymers having a molecular weight distribution (M_(w)/M_(n)) of less than about 3.0, or in some cases less than about 2.5.

In embodiments of the disclosure, a single site catalyst which gives an ethylene copolymer having a molecular weight distribution (M_(w)/M_(n)) of less than about 3.0, or less than about 2.7, or less than about 2.5, is used in the preparation of each of the first and the second ethylene copolymers.

In an embodiment of the disclosure, the first and second ethylene copolymers are prepared using an organometallic complex of a group 3, 4 or 5 metal that is further characterized as having a phosphinimine ligand. Such a complex, when active toward olefin polymerization, is known generally as a phosphinimine (polymerization) catalyst. Some non-limiting examples of phosphinimine catalysts can be found in U.S. Pat. Nos. 6,342,463; 6,235,672; 6,372,864; 6,984,695; 6,063,879; 6,777,509 and 6,277,931 all of which are incorporated by reference herein.

Some non-limiting examples of metallocene catalysts can be found in U.S. Pat. Nos. 4,808,561; 4,701,432; 4,937,301; 5,324,800; 5,633,394; 4,935,397; 6,002,033 and 6,489,413, which are incorporated herein by reference. Some non-limiting examples of constrained geometry catalysts can be found in U.S. Pat. Nos. 5,057,475; 5,096,867; 5,064,802; 5,132,380; 5,703,187 and 6,034,021, all of which are incorporated by reference herein in their entirety.

In an embodiment of the disclosure, use of a single site catalyst that does not produce long chain branching (LCB) is preferred. Hexyl (C6) branches detected by NMR are excluded from the definition of a long chain branch in the present disclosure.

In embodiments of the disclosure, the polyethylene copolymer composition has no long chain branching or has undetectable levels of long chain branching.

Without wishing to be bound by any single theory, long chain branching can increase viscosity at low shear rates, thereby negatively impacting cycle times during the manufacture of caps and closures, such as during the process of compression molding. Long chain branching may be determined using ¹³C NMR methods and may be quantitatively assessed using the method disclosed by Randall in Rev. Macromol. Chem. Phys. C29 (2 and 3), p. 285.

In an embodiment of the disclosure, the polyethylene copolymer composition will contain fewer than 0.3 long chain branches per 1000 carbon atoms. In another embodiment of the disclosure, the polyethylene copolymer composition will contain fewer than 0.01 long chain branches per 1000 carbon atoms.

In an embodiment of the disclosure, the polyethylene copolymer composition is prepared by contacting ethylene and at least one alpha-olefin with a polymerization catalyst under solution phase polymerization conditions in at least two polymerization reactors (for an example of solution phase polymerization conditions see for example U.S. Pat. Nos. 6,372,864 and 6,984,695 and U.S. Patent Application 20060247373A1).

In an embodiment of the disclosure, the polyethylene copolymer composition is prepared by contacting at least one single site polymerization catalyst system (comprising at least one single site catalyst and at least one activator) with ethylene and a least one comonomer (e.g., a C3-C8 alpha-olefin) under solution polymerization conditions in at least two polymerization reactors.

In an embodiment of the disclosure, a group 4 single site catalyst system, comprising a single site catalyst and an activator, is used in a solution phase dual reactor system to prepare a polyethylene copolymer composition by polymerization of ethylene in the presence of an alpha-olefin comonomer.

In an embodiment of the disclosure, a group 4 single site catalyst system, comprising a single site catalyst and an activator, is used in a solution phase dual reactor system to prepare a polyethylene copolymer composition by polymerization of ethylene in the presence of 1-octene.

In an embodiment of the disclosure, a group 4 phosphinimine catalyst system, comprising a phosphinimine catalyst and an activator, is used in a solution phase dual reactor system to prepare a polyethylene copolymer composition by polymerization of ethylene in the presence of an alpha-olefin comonomer.

In an embodiment of the disclosure, a group 4 phosphinimine catalyst system, comprising a phosphinimine catalyst and an activator, is used in a solution phase dual reactor system to prepare a polyethylene copolymer composition by polymerization of ethylene in the presence of 1-octene.

In an embodiment of the disclosure, a solution phase dual reactor system comprises two solution phase reactors connected in series.

In an embodiment of the disclosure, polymerization process to prepare the polyethylene copolymer composition comprises contacting at least one single site polymerization catalyst system (comprising at least one single site catalyst and at least one activator) with ethylene and at least one alpha-olefin comonomer under solution polymerization conditions in at least two polymerization reactors.

In an embodiment of the disclosure, a polymerization process to prepare the polyethylene copolymer composition comprises contacting at least one single site polymerization catalyst system with ethylene and at least one alpha-olefin comonomer under solution polymerization conditions in a first reactor and a second reactor configured in series.

In an embodiment of the disclosure, a polymerization process to prepare the polyethylene copolymer composition comprises contacting at least one single site polymerization catalyst system with ethylene and at least one alpha-olefin comonomer under solution polymerization conditions in a first reactor and a second reactor configured in series, with the at least one alpha-olefin comonomer being fed exclusively to the first reactor.

The production of the polyethylene copolymer composition of the present disclosure will typically include an extrusion or compounding step. Such steps are well known in the art.

The polyethylene copolymer composition can comprise further polymer components in addition to the first and second ethylene copolymers. Such polymer components include polymers made in situ or polymers added to the polymer composition during an extrusion or compounding step.

Optionally, additives can be added to the polyethylene copolymer composition. Additives can be added to the polyethylene copolymer composition during an extrusion or compounding step, but other suitable known methods will be apparent to a person skilled in the art. The additives can be added as is or as part of a separate polymer component (i.e. not the first or second ethylene copolymers described herein) or added as part of a masterbatch (optionally during an extrusion or compounding step). Suitable additives are known in the art and include but are not-limited to antioxidants, phosphites and phosphonites, nitrones, antacids, UV light stabilizers, UV absorbers, metal deactivators, dyes, fillers and reinforcing agents, nano-scale organic or inorganic materials, antistatic agents, lubricating agents such as calcium stearates, slip additives such as erucamide or behenamide, and nucleating agents (including nucleators, pigments or any other chemicals which may provide a nucleating effect to the polyethylene copolymer composition). The additives that can be optionally added are typically added in amount of up to 20 weight percent (wt %).

One or more nucleating agent(s) may be introduced into the polyethylene copolymer composition by kneading a mixture of the polymer, usually in powder or pellet form, with the nucleating agent, which may be utilized alone or in the form of a concentrate containing further additives such as stabilizers, pigments, antistatics, UV stabilizers and fillers. It should be a material which is wetted or absorbed by the polymer, which is insoluble in the polymer and of melting point higher than that of the polymer, and it should be homogeneously dispersible in the polymer melt in as fine a form as possible (1 to 10 μm). Compounds known to have a nucleating capacity for polyolefins include salts of aliphatic monobasic or dibasic acids or arylalkyl acids, such as sodium succinate, or aluminum phenylacetate; and alkali metal or aluminum salts of aromatic or alicyclic carboxylic acids such as sodium pi-naphthoate, or sodium benzoate.

Some non-limiting examples of nucleating agents which are commercially available and which may be added to the polyethylene copolymer composition are dibenzylidene sorbital esters (such as the products sold under the trademark MILLAD® 3988 by Milliken Chemical and IRGACLEAR® by Ciba Specialty Chemicals). Further non-limiting examples of nucleating agents which may be added to the polyethylene copolymer composition include the cyclic organic structures disclosed in U.S. Pat. No. 5,981,636 (and salts thereof, such as disodium bicyclo [2.2.1] heptene dicarboxylate); the saturated versions of the structures disclosed in U.S. Pat. No. 5,981,636 (as disclosed in U.S. Pat. No. 6,465,551; Zhao et al., to Milliken); the salts of certain cyclic dicarboxylic acids having a hexahydrophthalic acid structure (or “HHPA” structure) as disclosed in U.S. Pat. No. 6,599,971 (Dotson et al., to Milliken); and phosphate esters, such as those disclosed in U.S. Pat. No. 5,342,868 and those sold under the trade names NA-11 and NA-21 by Asahi Denka Kogyo, cyclic dicarboxylates and the salts thereof, such as the divalent metal or metalloid salts, (particularly, calcium salts) of the HHPA structures disclosed in U.S. Pat. No. 6,599,971. For clarity, the HHPA structure generally comprises a ring structure with six carbon atoms in the ring and two carboxylic acid groups which are substituents on adjacent atoms of the ring structure. The other four carbon atoms in the ring may be substituted, as disclosed in U.S. Pat. No. 6,599,971. An example is 1,2-cyclohexanedicarboxylicacid, calcium salt (CAS registry number 491589-22-1). Still further non-limiting examples of nucleating agents which may be added to the polyethylene copolymer composition include those disclosed in WO2015042561, WO2015042563, WO2015042562 and WO2011050042.

Many of the above described nucleating agents may be difficult to mix with the polyethylene copolymer composition that is being nucleated and it is known to use dispersion aids, such as for example, zinc stearate, to mitigate this problem.

In an embodiment of the disclosure, the nucleating agents are well dispersed in the polyethylene copolymer composition.

In an embodiment of the disclosure, the amount of nucleating agent used is comparatively small—from 100 to 4000 parts by million per weight (based on the weight of the polyethylene copolymer composition) so it will be appreciated by those skilled in the art that some care must be taken to ensure that the nucleating agent is well dispersed. In an embodiment of the disclosure, the nucleating agent is added in finely divided form (less than 50 microns, especially less than 10 microns) to the polyethylene copolymer composition to facilitate mixing. This type of “physical blend” (i.e. a mixture of the nucleating agent and the resin in solid form) may in an embodiment be preferable to the use of a “masterbatch” of the nucleator (where the term “masterbatch” refers to the practice of first melt mixing the additive—the nucleator, in this case—with a small amount of the polyethylene copolymer composition—then melt mixing the “masterbatch” with the remaining bulk of the polyethylene copolymer composition).

In an embodiment of the disclosure, an additive such as nucleating agent may be added to the polyethylene copolymer composition by way of a “masterbatch”, where the term “masterbatch” refers to the practice of first melt mixing the additive (e.g. a nucleator) with a small amount of the polyethylene copolymer composition, followed by melt mixing the “masterbatch” with the remaining bulk of the polyethylene copolymer composition.

In an embodiment of the disclosure, the polyethylene copolymer composition further comprises a nucleating agent.

In an embodiment of the disclosure, the polyethylene copolymer composition comprises from 20 to 4000 ppm (i.e. parts per million, based on the total weight of the first and the second ethylene copolymers in the polyethylene copolymer composition) of a nucleating agent.

In an embodiment of the disclosure, the polyethylene copolymer composition further comprises a nucleating agent which is a salt of a dicarboxylic acid compound. A dicarboxylic acid compound is herein defined as an organic compound containing two carboxyl (—COOH) functional groups. A salt of a dicarboxylic acid compound then will comprise one or more suitable cationic counter cations, preferably metal cations, and an organic compound having two anionic carboxylate (—COO⁻) groups.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of molded articles. Such articles may be formed by compression molding, continuous compression molding, injection molding or blow molding. Such articles include, for example, caps, screw caps, and closures, including hinged and tethered versions thereof, for bottles, containers, pouches, pill bottles, fitments, pharmaceutical bottles and the like.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of a fitment for bottles, pouches or the like.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in flexible packaging.

In an embodiment of the disclosure the polyethylene copolymer composition is used in the formation of films, such as for example, blown film, cast film and lamination or extrusion film or extrusion coating as well as stretch film. Processes to make such films from a polymer are well known to persons skilled in the art.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in an extrusion coating film layer.

In an embodiment of the disclosure the polyethylene copolymer composition is used in the formation of one or more than one film layer which is part of a multilayer layer film or film structure. Processes to makes such multilayer films or film structures are well known to persons skilled in the art.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of any closure, of any suitable design and dimensions for use in any hot filling process (or aseptic filling process) for filling any suitable bottle, container or the like.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of a closure for bottles, containers, pouches and the like.

For example, closures for bottles formed by continuous compression molding, or injection molding are contemplated. Such closures include, for example, caps, hinged caps, screw caps, hinged screw caps, snap-top caps, hinged snap-top caps, and optionally hinged closures for bottles, containers, pouches and the like.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of a fitment for a pouch, container or the like.

In an embodiment of the disclosure, the polyethylene copolymer composition is used in the formation of molded articles. For example, articles formed by continuous compression molding and injection molding are contemplated. Such articles include, for example, caps, screw caps, and closures for bottles.

Closures

The terms “cap” and “closure” are used interchangeably in the current disclosure, and both connote any suitably shaped molded article for enclosing, sealing, closing or covering etc., a suitably shaped opening, a suitably molded aperture, an open necked structure or the like used in combination with a container, a bottle, a jar, a pouch and the like.

Closures include one piece closures or closures comprising more than one piece.

In an embodiment of the disclosure, the polyethylene copolymer compositions described above are used in the formation of a closure.

In an embodiment of the disclosure, the polyethylene copolymer compositions described above are used in the formation of a one piece closure.

In an embodiment of the disclosure, the polyethylene copolymer compositions described above are used in the formation of a closure having a tamper evident band (a TEB).

In an embodiment of the disclosure, the polyethylene copolymer composition described above are used in the formation of a closure for bottles, containers, pouches and the like. For example, closures for bottles formed by compression molding or injection molding are contemplated. Such closures include, for example, hinged caps, hinged screw caps, hinged snap-top caps, and hinged closures for bottles, containers, pouches and the like.

In an embodiment of the disclosure, the polyethylene copolymer compositions described above are used in the formation of a bottle closure assembly comprising a cap portion, a tether portion and a retaining means portion.

In an embodiment of the disclosure, a closure (or cap) is a screw cap for a bottle, container, pouch and the like.

In an embodiment of the disclosure, a closure (or cap) is a snap closure for a bottle, container, pouch and the like.

In an embodiment of the disclosure, a closure (or cap) comprises a hinge made of the same material as the rest of the closure (or cap).

In an embodiment of the disclosure, a closure (or cap) is a hinged closure.

In an embodiment of the disclosure, a closure (or cap) is a hinged closure for bottles, containers, pouches and the like.

In an embodiment of the disclosure, a closure (or cap) is for retort, hot fill, aseptic fill and cold fill applications.

In an embodiment of the disclosure, a closure (or cap) is a flip-top hinge closure, such as a flip-top hinge closure for use on a plastic ketchup bottle or similar containers containing foodstuffs.

When a closure is a hinged closure, it comprises a hinged component and generally consists of at least two bodies which are connected by at least one thinner section that acts as a so called “living hinge” allowing the at least two bodies to bend from an initially molded position. The thinner section or sections may be continuous or web-like, wide or narrow.

A useful closure (for bottles, containers and the like) is a hinged closure and may consist of two bodies joined to each other by at least one thinner bendable portion (e.g. the two bodies can be joined by a single bridging portion, or more than one bridging portion, or by a webbed portion, etc.). A first body may contain a dispensing hole and which may snap onto or screw onto a container to cover a container opening (e.g. a bottle opening) while a second body may serve as a snap on lid which may mate with the first body.

The caps and closures, of which hinged caps and closures and screw caps are a subset, can be made according to any known method, including for example injection molding and compression molding techniques that are well known to persons skilled in the art. Hence, in an embodiment of the disclosure a closure (or cap) comprising the polyethylene copolymer composition (defined above) is prepared with a process comprising at least one compression molding step and/or at least one injection molding step.

In one embodiment, the caps and closures (including single piece or multi-piece variants and hinged variants) comprise the polyethylene copolymer composition described above which have good barrier properties, as well as good processability. Hence the closures and caps of this embodiment are well suited for sealing bottles, containers and the like, for examples bottles that may contain spoilable (for example, due to contact with oxygen) liquids or foodstuffs, including but not limited to liquids that are under an appropriate pressure (i.e. carbonated beverages or appropriately pressurized drinkable liquids).

The closures and caps may also be used for sealing bottles containing drinkable water or non-carbonated beverages (e.g. juice). Other applications, include caps and closures for bottles, containers and pouches containing foodstuffs, such as for example ketchup bottles and the like.

The closures and caps may be one-piece closures or two piece closures comprising a closure and a liner.

The closures and caps may also be of multilayer design, wherein the closure of cap comprises at least two layers at least one of which is made of the polyethylene copolymer compositions described herein.

In an embodiment of the disclosure the closure is made by continuous compression molding.

In an embodiment of the disclosure the closure is made by injection molding.

A closure as described in the present disclosure may be a closure suitable for use in a container sealing process comprising one of more steps in which the closure comes into contact with a liquid at elevated temperatures, such as a hot fill processes, and in some cases an aseptic fill processes. Such closures and processes are described in for example CA Pat. Appl. Nos 2,914,353; 2,914,354; and 2,914,315.

In an embodiment of the disclosure, a closure made is a PCO 1881 CSD closure, having a weight of about 2.15 grams and having the following dimensions: Closure height (not including Tamper Ring)=about 10.7 mm; Closure height with Tamper Ring=about 15.4 mm; Outside diameter @ 4 mm=about 29.6 mm; Thread diameter=about 25.5 mm; Bump seal diameter=about 24.5 mm; Bump seal thickness=about 0.7 mm; Bump seal height to center of olive=about 1.5 mm; Bore seal diameter=about 22.5 mm; Bore seal thickness=about 0.9 mm; Bore height to center of olive=about 1.6 mm; Top panel thickness=about 1.2 mm; Tamper band undercut diameter=about 26.3 mm; Thread depth=about 1.1 mm; Thread pitch=about 2.5 mm; Thread Root @ 4 mm=27.4 mm.

In an embodiment of the disclosure, a closure is made using an injection molding process to prepare a PCO 1881 CSD closure, having a weight of about 2.15 grams and having the following dimensions: Closure height (not including Tamper Ring)=about 10.7 mm; Closure height with Tamper Ring=about 15.4 mm; Outside diameter @ 4 mm=about 29.6 mm; Thread diameter=about 25.5 mm; Bump seal diameter=about 24.5 mm; Bump seal thickness=about 0.7 mm; Bump seal height to center of olive=about 1.5 mm; Bore seal diameter=about 22.5 mm; Bore seal thickness=about 0.9 mm; Bore height to center of olive=about 1.6 mm; Top panel thickness=about 1.2 mm; Tamper band undercut diameter=about 26.3 mm; Thread depth=about 1.1 mm; Thread pitch=about 2.5 mm; Thread Root @ 4 mm=27.4 mm.

In an embodiment of the disclosure, a closure is made using a continuous compression molding process to prepare a PCO 1881 CSD closure, having a weight of about 2.15 grams and having the following dimensions: Closure height (not including Tamper Ring)=about 10.7 mm; Closure height with Tamper Ring=about 15.4 mm; Outside diameter @ 4 mm=about 29.6 mm; Thread diameter=about 25.5 mm; Bump seal diameter=about 24.5 mm; Bump seal thickness=about 0.7 mm; Bump seal height to center of olive=about 1.5 mm; Bore seal diameter=about 22.5 mm; Bore seal thickness=about 0.9 mm; Bore height to center of olive=about 1.6 mm; Top panel thickness=about 1.2 mm; Tamper band undercut diameter=about 26.3 mm; Thread depth=about 1.1 mm; Thread pitch=about 2.5 mm; Thread Root @ 4 mm=27.4 mm.

In embodiments of the disclosure, a closure is made using a molding process to prepare a PCO 1881 CSD closure having a having an oxygen transmission rate, OTR of ≤0.0035 cm³/closure/day, or ≤0.0032 cm³/closure/day, or ≤0.0030 cm³/closure/day, or ≤0.0028 cm³/closure/day, or ≤0.0026 cm³/closure/day, or ≤0.0025 cm³/closure/day.

In an embodiment of the disclosure, a closure is made using a continuous compression molding process to prepare a PCO 1881 CSD closure having an oxygen transmission rate, OTR of ≤0.0035 cm³/closure/day, or ≤0.0032 cm³/closure/day, or ≤0.0030 cm³/closure/day, or ≤0.0028 cm³/closure/day, or ≤0.0026 cm³/closure/day, or ≤0.0025 cm³/closure/day.

In an embodiment of the disclosure, a closure is made using an injection molding process to prepare a PCO 1881 CSD closure having a having an oxygen transmission rate, OTR of ≤0.0035 cm³/closure/day, or ≤0.0032 cm³/closure/day, or ≤0.0030 cm³/closure/day, or ≤0.0028 cm³/closure/day, or ≤0.0026 cm³/closure/day, or ≤0.0025 cm³/closure/day.

In embodiments of the disclosure, a closure is made using a molding process to prepare a PCO 1881 CSD closure having an oxygen transmission rate, OTR of from 0.0016 to 0.0035 cm³/closure/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a closure is made using a molding process to prepare a PCO 1881 CSD closure having an oxygen transmission rate, OTR of from 0.0016 to 0.0033 cm³/closure/day, or from 0.0016 to 0.0032 cm³/closure/day, or from 0.0016 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0028 cm³/closure/day, or from 0.0020 to 0.0030 cm³/closure/day, or from 0.0020 to 0.0028 cm³/closure/day.

In an embodiment of the disclosure, a closure is made using a continuous compression molding process to prepare a PCO 1881 CSD closure having an oxygen transmission rate, OTR of from 0.0016 to 0.0035 cm³/closure/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a closure is made using a continuous compression molding process to prepare a PCO 1881 CSD closure having an oxygen transmission rate, OTR of from 0.0016 to 0.0033 cm³/closure/day, or from 0.0016 to 0.0032 cm³/closure/day, or from 0.0016 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0028 cm³/closure/day, or from 0.0020 to 0.0030 cm³/closure/day, or from 0.0020 to 0.0028 cm³/closure/day.

In an embodiment of the disclosure, a closure is made using an injection molding process to prepare a PCO 1881 CSD closure having a having an oxygen transmission rate, OTR of from 0.0016 to 0.0035 cm³/closure/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a closure is made using an injection molding process to prepare a PCO 1881 CSD closure having a having an oxygen transmission rate, OTR of from 0.0016 to 0.0033 cm³/closure/day, or from 0.0016 to 0.0032 cm³/closure/day, or from 0.0016 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0030 cm³/closure/day, or from 0.0018 to 0.0028 cm³/closure/day, or from 0.0020 to 0.0030 cm³/closure/day, or from 0.0020 to 0.0028 cm³/closure/day.

Cast (and Lamination) Film

In an embodiment of the disclosure, the polyethylene copolymer compositions described above are used in the formation of a cast film or laminate film.

Cast films are extruded from a flat die onto a chilled roll or a nipped roll, optionally, with a vacuum box and/or air-knife. The films may be monolayer or coextruded multi-layer films obtained by various extrusion through a single or multiple dies. The resultant films may be the used as-is or may be laminated to other films or substrates, for example by thermal, adhesive lamination or direct extrusion onto a substrate. The resultant films and laminates may be subjected to other forming operations such as embossing, stretching, thermoforming. Surface treatments such as corona may be applied and the films may be printed.

In the cast film extrusion process, a thin film is extruded through a slit onto a chilled, highly polished turning roll, where it is quenched from one side. The speed of the roller controls the draw ratio and final film thickness. The film is then sent to a second roller for cooling on the other side. Finally, it passes through a system of rollers and is wound onto a roll. In another embodiment, two or more thin films are coextruded through two or more slits onto a chilled, highly polished turning roll, the coextruded film is quenched from one side. The speed of the roller controls the draw ratio and final coextruded film thickness. The coextruded film is then sent to a second roller for cooling on the other side. Finally, it passes through a system of rollers and is wound onto a roll.

In an embodiment, the cast film product may further be laminated one or more layers into a multilayer structure.

The cast films and laminates may be used in a variety of purposes, for example food packaging (dry foods, fresh foods, frozen foods, liquids, processed foods, powders, granules), for packaging of detergents, toothpaste, towels, for labels and release liners. The films may also be used in unitization and industrial packaging, notably in stretch films. The films may also be suitable in hygiene and medical applications, for example in breathable and non-breathable films used in diapers, adult incontinence products, feminine hygiene products, ostomy bags. Finally, cast films may also be used in tapes and artificial turf applications.

In embodiments of the disclosure, a film or film layer has a normalized oxygen transmission rate, OTR of ≤120 cm³/100 in²/day, or ≤110 cm³/100 in²/day, or ≤100 cm³/100 in²/day, or ≤95 cm³/100 in²/day.

In embodiments of the disclosure, a compression molded film or film layer has a normalized oxygen transmission rate, OTR of ≤120 cm³/100 in²/day, or ≤110 cm³/100 in²/day, or ≤100 cm³/100 in²/day, or ≤95 cm³/100 in²/day.

In embodiments of the disclosure, a cast film or film layer has a normalized oxygen transmission rate, OTR of ≤120 cm³/100 in²/day, or ≤110 cm³/100 in²/day, or ≤100 cm³/100 in²/day, or ≤95 cm³/100 in²/day.

In embodiments of the disclosure, a lamination film or film layer has a normalized oxygen transmission rate, OTR of ≤120 cm³/100 in²/day, or ≤110 cm³/100 in²/day, or ≤100 cm³/100 in²/day, or ≤95 cm³/100 in²/day.

In embodiments of the disclosure, a film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 120 cm³/100 in²/day, including any narrower ranges within this range and any values encompassed by these ranges.

For example, in embodiments of the disclosure, a film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 110 cm³/100 in²/day, or from 60 to 100 cm³/100 in²/day, or from 60 to 95 cm³/100 in²/day, or from 65 to 100 cm³/100 in²/day, or from 65 to 95 cm³/100 in²/day.

In embodiments of the disclosure, a compression molded film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 120 cm³/100 in²/day, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a compression molded film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 110 cm³/100 in²/day, or from 60 to 100 cm³/100 in²/day, or from 60 to 95 cm³/100 in²/day, or from 65 to 100 cm³/100 in²/day, or from 65 to 95 cm³/100 in²/day.

In embodiments of the disclosure, a cast film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 120 cm³/100 in²/day, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a cast film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 110 cm³/100 in²/day, or from 60 to 100 cm³/100 in²/day, or from 60 to 95 cm³/100 in²/day, or from 65 to 100 cm³/100 in²/day, or from 65 to 95 cm³/100 in²/day.

In embodiments of the disclosure, a lamination film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 120 cm³/100 in²/day, including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a lamination film or film layer has a normalized oxygen transmission rate, OTR of from 60 to 110 cm³/100 in²/day, or from 60 to 100 cm³/100 in²/day, or from 60 to 95 cm³/100 in²/day, or from 65 to 100 cm³/100 in²/day, or from 65 to 95 cm³/100 in²/day.

In embodiments of the disclosure, a film or film layer has a normalized water vapor transmission rate, WVTR of ≤0.300 g/100 in²/day, or ≤0.280 g/100 in²/day, or ≤0.260 g/100 in²/day, or ≤0.250 g/100 in²/day, or ≤0.240 g/100 in²/day, or ≤0.230 g/100 in²/day.

In embodiments of the disclosure, a compression molded film or film layer has a normalized water vapor transmission rate, WVTR of ≤0.300 g/100 in²/day, or ≤0.280 g/100 in²/day, or ≤0.260 g/100 in²/day, or ≤0.250 g/100 in²/day, or ≤0.240 g/100 in²/day, or ≤0.230 g/100 in²/day.

In embodiments of the disclosure, a cast film or film layer has a normalized water vapor transmission rate, WVTR of ≤0.300 g/100 in²/day, or ≤0.280 g/100 in²/day, or ≤0.260 g/100 in²/day, or ≤0.250 g/100 in²/day, or ≤0.240 g/100 in²/day, or ≤0.230 g/100 in²/day.

In embodiments of the disclosure, a lamination film or film layer has a normalized water vapor transmission rate, WVTR of ≤0.300 g/100 in²/day, or ≤0.280 g/100 in²/day, or ≤0.260 g/100 in²/day, or ≤0.250 g/100 in²/day, or ≤0.240 g/100 in²/day, or ≤0.230 g/100 in²/day.

In embodiments of the disclosure, a film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.300 g/100 in²/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.280 g/100 in²/day, or from 0.160 to 0.260 g/100 in²/day, or from 0.160 to 0.250 g/100 in²/day, or from 0.160 to 0.240 g/100 in²/day, or from 0.180 to 0.280 g/100 in²/day, or from 0.180 to 0.260 g/100 in²/day, or from 0.180 to 0.250 g/100 in²/day, or from 0.180 to 0.240 g/100 in²/day.

In embodiments of the disclosure, a compression molded film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.300 g/100 in²/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a compression molded film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.280 g/100 in²/day, or from 0.160 to 0.260 g/100 in²/day, or from 0.160 to 0.250 g/100 in²/day, or from 0.160 to 0.240 g/100 in²/day, or from 0.180 to 0.280 g/100 in²/day, or from 0.180 to 0.260 g/100 in²/day, or from 0.180 to 0.250 g/100 in²/day, or from 0.180 to 0.240 g/100 in²/day.

In embodiments of the disclosure, a cast film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.300 g/100 in²/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a cast film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.280 g/100 in²/day, or from 0.160 to 0.260 g/100 in²/day, or from 0.160 to 0.250 g/100 in²/day, or from 0.160 to 0.240 g/100 in²/day, or from 0.180 to 0.280 g/100 in²/day, or from 0.180 to 0.260 g/100 in²/day, or from 0.180 to 0.250 g/100 in²/day, or from 0.180 to 0.240 g/100 in²/day.

In embodiments of the disclosure, a lamination film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.300 g/100 in²/day including any narrower ranges within this range and any values encompassed by these ranges. For example, in embodiments of the disclosure, a lamination film or film layer has a normalized water vapor transmission rate, WVTR of from 0.160 to 0.280 g/100 in²/day, or from 0.160 to 0.260 g/100 in²/day, or from 0.160 to 0.250 g/100 in²/day, or from 0.160 to 0.240 g/100 in²/day, or from 0.180 to 0.280 g/100 in²/day, or from 0.180 to 0.260 g/100 in²/day, or from 0.180 to 0.250 g/100 in²/day, or from 0.180 to 0.240 g/100 in²/day.

Further non-limiting details of the disclosure are provided in the following examples. The examples are presented for the purposes of illustrating selected embodiments of this disclosure, it being understood that the examples presented do not limit the claims presented.

EXAMPLES General Polymer Characterization Methods

Prior to testing, each specimen was conditioned for at least 24 hours at 23±2° C. and 50±10% relative humidity and subsequent testing was conducted at 23±2° C. and 50±10% relative humidity. Herein, the term “ASTM conditions” refers to a laboratory that is maintained at 23±2° C. and 50±10% relative humidity, and specimens to be tested were conditioned for at least 24 hours in this laboratory prior to testing. ASTM refers to the American Society for Testing and Materials.

Density was determined using ASTM D792-13 (Nov. 1, 2013).

Melt index was determined using ASTM D1238 (Aug. 1, 2013). Melt indexes, I₂, I₆, I₁₀ and I₂₁ were measured at 190° C., using weights of 2.16 kg, 6.48 kg, 10 kg and a 21.6 kg respectively. Herein, the term “stress exponent” or its acronym “S.Ex.”, is defined by the following relationship: S.Ex.=log (I₆/I₂)/log(6480/2160); wherein 16 and 12 are the melt flow rates measured at 190° C. using 6.48 kg and 2.16 kg loads, respectively.

M_(n), M_(w), and M_(z)(g/mol) were determined by high temperature Gel Permeation Chromatography (GPC) with differential refractive index (DRI) detection using universal calibration (e.g. ASTM-D6474-99). GPC data was obtained using an instrument sold under the trade name “Waters 150c”, with 1,2,4-trichlorobenzene as the mobile phase at 140° C. The samples were prepared by dissolving the polymer in this solvent and were run without filtration. Molecular weights are expressed as polyethylene equivalents with a relative standard deviation of 2.9% for the number average molecular weight (“M_(n)”) and 5.0% for the weight average molecular weight (“M_(w)”). The molecular weight distribution (MWD) is the weight average molecular weight divided by the number average molecular weight, M_(w)/M_(n). The z-average molecular weight distribution is M_(Z)/M_(n). Polymer sample solutions (1 to 2 mg/mL) were prepared by heating the polymer in 1,2,4-trichlorobenzene (TCB) and rotating on a wheel for 4 hours at 150° C. in an oven. The antioxidant 2,6-di-tert-butyl-4-methylphenol (BHT) was added to the mixture in order to stabilize the polymer against oxidative degradation. The BHT concentration was 250 ppm. Sample solutions were chromatographed at 140° C. on a PL 220 high-temperature chromatography unit equipped with four SHODEX® columns (HT803, HT804, HT805 and HT806) using TCB as the mobile phase with a flow rate of 1.0 mL/minute, with a differential refractive index (DRI) as the concentration detector. BHT was added to the mobile phase at a concentration of 250 ppm to protect the columns from oxidative degradation. The sample injection volume was 200 mL. The raw data were processed with CIRRUS® GPC software. The columns were calibrated with narrow distribution polystyrene standards. The polystyrene molecular weights were converted to polyethylene molecular weights using the Mark-Houwink equation, as described in the ASTM standard test method D6474.

High temperature GPC equipped with an online FTIR detector (GPC-FTIR) was used to measure the comonomer content as the function of molecular weight.

Primary melting peak (° C.), heat of fusion (J/g) and crystallinity (%) was determined using differential scanning calorimetry (DSC) as follows: the instrument was first calibrated with indium; after the calibration, a polymer specimen is equilibrated at 0° C. and then the temperature was increased to 200° C. at a heating rate of 10° C./min; the melt was then kept isothermally at 200° C. for five minutes; the melt was then cooled to 0° C. at a cooling rate of 10° C./min and kept at 0° C. for five minutes; the specimen was then heated to 200° C. at a heating rate of 10° C./min. The DSC™, heat of fusion and crystallinity are reported from the 2^(nd) heating cycle.

The short chain branch frequency (SCB per 1000 carbon atoms) of the polyethylene composition was determined by Fourier Transform Infrared Spectroscopy (FTIR) as per the ASTM D6645-01 method. A Thermo-Nicolet™ 750 Magna-IR Spectrophotometer equipped with OMNIC version 7.2a software was used for the measurements. Unsaturations in the polyethylene composition were also determined by Fourier Transform Infrared Spectroscopy (FTIR) as per ASTM D3124-98.

Hexane extractables were determined according to ASTM D5227.

Shear viscosity was measured by using a Kayeness WinKARS Capillary Rheometer (model #D5052M-115). For the shear viscosity at lower shear rates, a die having a die diameter of 0.06 inch and L/D ratio of 20 and an entrance angle of 180 degrees was used. For the shear viscosity at higher shear rates, a die having a die diameter of 0.012 inch and L/D ratio of 20 was used.

The Shear Viscosity Ratio as the term is used in the present disclosure is defined as: η₁₀₀/η₁₀₀₀₀₀ at 240° C. The processability indicator is defined as 100/η₁₀₀₀₀₀₀. The η₁₀₀ is the melt shear viscosity at the shear rate of 100 s⁻¹ and the η₁₀₀₀₀₀ is the melt shear viscosity at the shear rate of 100000 s⁻¹ measured at 240° C.

The “processability indicator” as used herein is defined as: processability Indicator=100/η(105 s⁻¹, 240° C.); where η is the shear viscosity measured at 10⁵ 1/s at 240° C.

Dynamic mechanical analyses were carried out with a rheometer, namely Rheometrics Dynamic Spectrometer (RDS-II) or Rheometrics SR5 or ATS Stresstech, on compression molded samples under nitrogen atmosphere at 190° C., using 25 mm diameter cone and plate geometry. The oscillatory shear experiments were done within the linear viscoelastic range of strain (10% strain) at frequencies from 0.05 to 100 rad/s. The values of storage modulus (G′), loss modulus (G″), complex modulus (G*) and complex viscosity (η*) were obtained as a function of frequency. The same rheological data can also be obtained by using a 25 mm diameter parallel plate geometry at 190° C. under nitrogen atmosphere. The Zero shear viscosity is estimated using the Ellis model, i.e. η(ω)=η₀/(1+τ/τ_(1/2))^(α-1), where η₀ is the zero shear viscosity. τ_(1/2) is the value of the shear stress at which η=η₀/2 and a is one of the adjustable parameters. The Cox-Merz rule is assumed to be applicable in the present disclosure. The SHI(1,100) value is calculated according to the methods described in WO 2006/048253 and WO 2006/048254.

The DRI, is the “dow rheology index”, and is defined by the equation: DRI=[365000(τ₀/η₀)−1]/10, wherein τ₀ is the characteristic relaxation time of the polyethylene and η₀ is the zero shear viscosity of the material. The DRI is calculated by least squares fit of the rheological curve (dynamic complex viscosity versus applied frequency e.g. 0.01-100 rads/s) as described in U.S. Pat. No. 6,114,486 with the following generalized Cross equation, i.e. η(ω)=η₀/[1+(ωτ₀)^(n)]; wherein n is the power law index of the material, η(ω) and ω are the measured complex viscosity and applied frequency data respectively. When determining the DRI, the zero shear viscosity, η₀ used was estimated with the Ellis model, rather than the Cross model.

The crossover frequency is the frequency at which storage modulus (G′) and loss modulus (G″) curves cross with each other, while G′@G″=500 Pa is the storage modulus at which the loss modulus (G″) is at 500 Pa.

To determine CDBI(50), a solubility distribution curve is first generated for the polyethylene composition. This is accomplished using data acquired from the TREF technique. This solubility distribution curve is a plot of the weight fraction of the copolymer that is solubilized as a function of temperature. This is converted to a cumulative distribution curve of weight fraction versus comonomer content, from which the CDBI(50) is determined by establishing the weight percentage of a copolymer sample that has a comonomer content within 50% of the median comonomer content on each side of the median (See WO 93/03093 and U.S. Pat. No. 5,376,439). Those skilled in the art will understand that a calibration curve is required to convert a TREF elution temperature to comonomer content, i.e. the amount of comonomer in the polyethylene composition fraction that elutes at a specific temperature. The generation of such calibration curves are described in the prior art, e.g. Wild et al., J. Polym. Sci., Part B, Polym. Phys., Vol. 20 (3), pages 441-455: hereby fully incorporated by reference. The CDBI(25) is determined by establishing the weight percentage of a copolymer sample that has a comonomer content within 25% of the median comonomer content on each side of the median.

The temperature rising elution fractionation (TREF) method used herein was as follows. Polymer samples (50 to 150 mg) were introduced into the reactor vessel of a crystallization-TREF unit (Polymer Char, Valencia Technology Park, Gustave Eiffel, 8, Paterna, E-46980 Valencia, Spain) equipped with an IR detector. The reactor vessel was filled with 20 to 40 ml 1,2,4-trichlorobenzene (TCB), and heated to the desired dissolution temperature (e.g., 150° C.) for 1 to 3 hours. The solution (0.5 to 1.5 ml) was then loaded into the TREF column filled with stainless steel beads. After equilibration at a given stabilization temperature (e.g., 110° C.) for 30 to 45 minutes, the polymer solution was allowed to crystallize with a temperature drop from the stabilization temperature to 30° C. (0.1 or 0.2° C./minute). After equilibrating at 30° C. for 30 minutes, the crystallized sample was eluted with TCB (0.5 or 0.75 mL/minute) with a temperature ramp from 30° C. to the stabilization temperature (0.25 or 1.0° C./minute). The TREF column was cleaned at the end of the run for 30 minutes at the dissolution temperature. The data were processed using Polymer Char software, Excel spreadsheet and TREF software developed in-house. Using Polymer Char software a TREF distribution curve was generated as the polyethylene composition was eluted from the TREF column, i.e. a TREF distribution curve is a plot of the quantity (or intensity) of polyethylene composition eluting from the column as a function of TREF elution temperature. The crystallization-TREF was operated in the TREF mode, which generated the chemical composition of the polymer sample as a function of elution temperature, the Co/Ho ratio (Copolymer/Homopolymer ratio), the CDBI (the Composition Distribution Breadth Index), i.e. CDBI(50) and CDBI(25), the location of a high temperature elution peak (in ° C.) and the approximate amount of a high density fraction (a “HD fraction”, in weight percent) which elutes at a temperature of from 95 to 105° C.

Plaques molded from the polyethylene copolymer compositions were tested according to the following ASTM methods: Bent Strip Environmental Stress Crack Resistance (ESCR) at Condition B at 100% IGEPAL at 50° C., ASTM D1693; notched Izod impact properties, ASTM D256; Flexural Properties, ASTM D 790; Tensile properties, ASTM D 638; Vicat softening point, ASTM D 1525; Heat deflection temperature, ASTM D 648.

Examples of the polyethylene copolymer compositions were produced in a dual reactor solution polymerization process in which the contents of the first reactor flow into the second reactor. This in-series “dual reactor” process produces an “in-situ” polyethylene blend (i.e., the polyethylene composition). Note, that when an in-series reactor configuration is used, un-reacted ethylene monomer, and un-reacted alpha-olefin comonomer present in the first reactor, will flow into the downstream second reactor for further polymerization.

In the present inventive examples, although no co-monomer is feed directly to the downstream second reactor, an ethylene copolymer is nevertheless formed in second reactor due to the significant presence of un-reacted 1-octene flowing from the first reactor to the second reactor where it is copolymerized with ethylene. Each reactor is sufficiently agitated to give conditions in which components are well mixed. The volume of the first reactor was 12 liters and the volume of the second reactor was 22 liters. These are the pilot plant scales. The first reactor was operated at a pressure of 10500 to 35000 kPa and the second reactor was operated at a lower pressure to facilitate continuous flow from the first reactor to the second. The solvent employed was methylpentane. The process operates using continuous feed streams. The catalyst employed in the dual reactor solution process experiments was a phosphinimine catalyst, which was a titanium complex having a phosphinimine ligand ((tert-butyl)₃P═N), a cyclopentadienide ligand (Cp) and two activatable ligands (chloride ligands; note: “activatable ligands” are removed, by for example electrophilic abstraction using a co-catalyst or activator to generate an active metal center). A boron based co-catalyst (Ph₃CB(C₆F₅)₄) was used in approximately stoichiometric amounts relative to the titanium complex. Commercially available methylaluminoxane (MAO) was included as a scavenger at an Al:Ti of about 40:1. In addition, 2,6-di-tert-butylhydroxy-4-ethylbenzene was added to scavenge free trimethylaluminum within the MAO in a ratio of Al:OH of about 0.5:1. The polymerization conditions used to make the inventive polyethylene copolymer compositions are provided in Table 1.

The polyethylene copolymer compositions of Examples 1-3 which are inventive are made using a single site phosphinimine catalyst in a dual reactor solution process as described above.

As can be seen in FIG. 1, the inventive Examples 1-3 have a unimodal molecular weight distribution or profile in a GPC analysis.

Comparative polyethylene homopolymer compositions, Examples 4-6 were prepared in a dual reactor solution polymerization process using a phosphinimine catalyst, as described in co-pending CA Pat. Application No. 3,026,098.

Comparative polyethylene homopolymer compositions, Examples 7 and 8, which were nucleated with HYPERFORM® HPN-20E (which can be obtained commercially from Milliken Chemical) in the same manner and at the same amounts as Examples 1-6 (see below), were prepared in a dual reactor solution polymerization process using a phosphinimine catalyst, in a manner substantially as outlined in U.S. Pat. No. 7,737,220 and U.S. Pat. Pub. Nos. 2008/0118749 and 2015/0203671 each of which are incorporated herein in their entirety.

Non-nucleated and nucleated Inventive and as well Comparative polyethylene composition properties are provided in Table 2. The nucleated Inventive resins (Examples 1-3) and the nucleated Comparative resins (Examples 4-6) which are denoted in the Tables with the symbol “*”, were prepared in the following manner. A 4% (by weight) masterbatch of HYPERFORM HPN-20E nucleating agent from Milliken Chemical was first prepared. This masterbatch also contained 1% (by weight) of DHT-4V (aluminium magnesium carbonate hydroxide) from Kisuma Chemicals. The base resin and the nucleating agent masterbatch were then melt blended using a Coperion ZSK 26 co-rotating twin screw extruder with an L/D of 32:1 to give a polyethylene composition having 1200 parts per million (ppm) of the HYPERFORM HPN-20E nucleating agent present (based on the weight of the polyethylene composition). The extruder was fitted with an underwater pelletizer and a Gala spin dryer. The materials were co-fed to the extruder using gravimetric feeders to achieve the desired nucleating agent level. The blends were compounded using a screw speed of 200 rpm at an output rate of 15-20 kg/hour and at a melt temperature of 225-230° C.

Some calculated properties for the first ethylene copolymer and the second ethylene copolymer present in each of the inventive polyethylene copolymer compositions (Examples 1-3) are provided in Table 3 (see “Polymerization Reactor Modeling” below for methods of calculating these properties). For comparison purposes, Table 3 also includes some calculated properties for the first and second ethylene homopolymers present in the comparative polyethylene compositions of Examples 4-8 (for methods of calculating these properties see co-pending CA Pat. Application No. 3,026,098).

The properties of pressed plaques made from non-nucleated and nucleated inventive polyethylene copolymer compositions as well as comparative compositions are provided in Table 4.

Polymerization Reactor Modeling

For multicomponent (or bimodal resins) polyethylene polymers with very low comonomer content, it can be difficult to reliably estimate the short chain branching (and subsequently polyethylene resin density by combining other information) of each polymer component by mathematical deconvolution of GPC-FTIR data, as was done in for example U.S. Pat. No. 8,022,143. Instead, the M_(w), M_(n), M_(z), M_(w)/M_(n) and the short chain branching per thousand carbons (SCB/1000C) of the first and second copolymers were calculated herein, by using a reactor model simulation using the input conditions which were employed for actual pilot scale run conditions (for references on relevant reactor modeling methods, see “Copolymerization” by A. Hamielec, J. MacGregor, and A. Penlidis in Comprehensive Polymer Science and Supplements, volume 3, Chapter 2, page 17, Elsevier, 1996 and “Copolymerization of Olefins in a Series of Continuous Stirred-Tank Slurry-Reactors using Heterogeneous Ziegler-Natta and Metallocene Catalysts. I. General Dynamic Mathematical Model” by J. B. P. Soares and A. E. Hamielec in Polymer Reaction Engineering, 4(2&3), p 153, 1996.) This type of model is considered reliable for the estimate of comonomer (e.g. 1-octene) content even at low comonomer incorporation levels, since the ethylene conversion, ethylene input flow and comonomer input flow can be obtained directly from the experimental conditions and because the reactive ratio (see below) can be reliably estimated for the catalyst system used in the present disclosure. For clarity the “monomer” or “monomer 1” represent ethylene, while the terms “comonomer” or “monomer 2”, represent 1-octene.

The model takes for input the flow of several reactive species (e.g. catalyst, monomer such as ethylene, comonomer such as 1-octene, hydrogen, and solvent) going to each reactor, the temperature (in each reactor), and the conversion of monomer (in each reactor), and calculates the polymer properties (of the polymer made in each reactor, i.e. the first and second ethylene copolymers) using a terminal kinetic model for continuously stirred tank reactors (CSTRs) connected in series. The “terminal kinetic model” assumes that the kinetics depend upon the monomer unit within the polymer chain on which the active catalyst site is located (see “Copolymerization” by A. Hamielec, J. MacGregor, and A. Penlidis in Comprehensive Polymer Science and Supplements, volume 3, Chapter 2, page 17, Elsevier, 1996). In the model, the copolymer chains are assumed to be of reasonably large molecular weight to ensure that the statistics of monomer/comonomer unit insertion at the active catalyst center is valid and that monomers/comonomers consumed in routes other than propagation are negligible. This is known as the “long chain” approximation.

The terminal kinetic model for polymerization includes reaction rate equations for activation, initiation, propagation, chain transfer, and deactivation pathways. This model solves the steady-state conservation equations (e.g. the total mass balance and heat balance) for the reactive fluid which comprises the reactive species identified above.

The total mass balance for a generic CSTR with a given number of inlets and outlets is given by:

0=Σ_(i) {dot over (m)} _(i)  (1)

where {dot over (m)}_(i) represents the mass flow rate of individual streams with index i indicating the inlet and outlet streams.

Equation (1) can be further expanded to show the individual species and reactions:

$\begin{matrix} {0 = {\frac{\sum_{i}{m{{\overset{.}{x}}_{ij}/M_{i}}}}{\rho_{mix}V} + {R_{j}/\rho_{mix}}}} & (2) \end{matrix}$

where M_(i) is the average molar weight of the fluid inlet or outlet (i), x_(ij) is the mass fraction of species j in stream i, ρ_(mix) is the molar density of the reactor mixture, V is the reactor volume, R_(j) is the reaction rate for species j, which has units of kmol/m³s.

The total heat balance is solved for an adiabatic reactor and is given by:

0=(Σ{dot over (m)} _(i) ΔH _(i) +q _(Rx) V+{dot over (W)}−{dot over (Q)})  (3)

where, {dot over (m)}_(i) is the mass flow rate of stream i (inlet or outlet), ΔH_(i) is the difference in enthalpy of stream i versus a reference state, q_(Rx) is the heat released by reaction(s), V is the reactor volume, {dot over (W)} is the work input (i.e. agitator), {dot over (Q)} is the heat input/loss.

The catalyst concentration input to each reactor is adjusted to match the experimentally determined ethylene conversion and reactor temperature values in order solve the equations of the kinetic model (e.g. propagation rates, heat balance and mass balance).

The H₂ concentration input to each reactor may be likewise adjusted so that the calculated molecular weight distribution of a polymer made over both reactors (and hence the molecular weight of polymer made in each reactor) matches that which is observed experimentally.

The degree of polymerization (DPN) for a polymerization reaction is given by the ratio of the rate of chain propagation reactions over the rate of chain transfer/termination reactions:

$\begin{matrix} {{DPN} = \frac{{k_{p11}{\phi_{1}\left\lbrack m_{1} \right\rbrack}} + {k_{p12}{\phi_{1}\left\lbrack m_{2} \right\rbrack}} + {k_{p21}{\phi_{2}\left\lbrack m_{2} \right\rbrack}}}{\begin{matrix} {{{k_{{tm}\; 11}\left\lbrack m_{1} \right\rbrack}\phi_{1}} + {{k_{{tm}\; 12}\left\lbrack m_{2} \right\rbrack}\phi_{1}} + {{k_{{tm}\; 21}\left\lbrack m_{2} \right\rbrack}\phi_{2}} +} \\ {{k_{{ts}\; 1}\phi_{1}} + {k_{{ts}\; 2}\phi_{2}} + {k_{{tH}\; 1}\lbrack H\rbrack} + {k_{{tH}\; 2}\lbrack H\rbrack}} \end{matrix}}} & (4) \end{matrix}$

where k_(p12) is the propagation rate constant for adding monomer 2 to a growing polymer chain ending with monomer 1, [m₁] is the molar concentration of monomer 1 (ethylene) in the reactor, [m₂] is the molar concentration of monomer 2 (1-octene) in the reactor, k_(tm12) the termination rate constant for chain transfer to monomer 2 for a growing chain ending with monomer 1, k_(ts1) is rate constant for the spontaneous chain termination for a chain ending with monomer 1, k_(tH1) is the rate constant for the chain termination by hydrogen for a chain ending with monomer 1. ϕ₁ and ϕ₂ and the fraction of catalyst sites occupied by a chain ending with monomer 1 or monomer 2 respectively.

The number average molecular weight (Mn) for a polymer follows from the degree of polymerization and the molecular weight of a monomer unit. From the number average molecular weight of polymer in each reactor, and assuming a Flory distribution for a single site catalyst, the molecular weight distribution is determined for the polymer formed in each reactor:

$\begin{matrix} {{{w(n)} = {{\tau^{2}ne^{{- \tau}n}\mspace{14mu}{where}\mspace{14mu}\tau} = \frac{1}{DPN}}},} & (5) \end{matrix}$

and w(n) is the weight fraction of polymer having a chain length n. The Flory distribution can be transformed into the common log scaled GPC trace by applying:

$\begin{matrix} {\frac{dW}{d\;{\log(M)}} = {{\ln\left( {10} \right)}\frac{n^{2}}{{DPN}^{2}}e^{({- \frac{n}{DPN}})}\mspace{14mu}{where}\mspace{14mu}\frac{dW}{d\;{\log\left( {MW} \right)}}}} & (6) \end{matrix}$

is the differential weight fraction of polymer with a chain length n (n=MW/28 where 28 is the molecular weight of the polymer segment corresponding to a C₂H₄ unit) and DPN is the degree of polymerization as calculated by Equation (4). From the Flory model, the M_(w) and the M_(z) of the polymer made in each reactor are: M_(w)=2×M_(n) and M_(z)=1.5×M_(w).

The overall molecular weight distribution over both reactors is simply the sum of the molecular weight distribution of polymer made in each reactor, and where each Flory distribution is multiplied by the weight fraction of polymer made in each reactor:

$\begin{matrix} {\frac{d\overset{\_}{W}}{d\;{\log\left( {MW} \right)}} = {{W_{R1}\left( {{\ln\left( {10} \right)}\frac{n^{2}}{{DPN}_{R\; 1}^{2}}e^{({- \frac{n}{DPN_{R1}}})}} \right)} + {W_{R2}\left( {{\ln\left( {10} \right)}\frac{n^{2}}{{DPN}_{R\; 2}^{2}}e^{({- \frac{n}{DPN_{R2}}})}} \right)}}} & (7) \end{matrix}$

where dW/d log(MW) is the overall molecular weight distribution function, w_(R1) and w_(R2) are the weight fraction of polymer made in each reactor, DPN₁ and DPN₂ is the average chain length of the polymer made in each reactor (i.e. DPN₁=M_(nR1)/28). The weight fraction of material made in each reactor is determined from knowing the mass flow of monomer and comonomer into each reactor along with knowing the conversions for monomer and comonomer in each reactor.

The moments of the overall molecular weight distribution (or the molecular weight distribution of polymer made in each reactor) can be calculated using equations 8a, 8b and 8c (a Flory Model is assumed above, but the below generic formula apply to other model distributions as well):

$\begin{matrix} {\overset{\_}{M_{n}} = \frac{\sum_{i}w_{i}}{\sum_{i}\frac{w_{i}}{M_{i}}}} & \left( {8a} \right) \\ {\overset{\_}{M_{w}} = \frac{\sum_{i}{w_{i}M_{i}}}{\sum_{i}w_{i}}} & \left( {8b} \right) \\ {\overset{\_}{M_{z}} = \frac{\sum_{i}{w_{i}M_{i}^{2}}}{\sum_{i}{w_{i}M_{i}}}} & \left( {8c} \right) \end{matrix}$

The comonomer content in the polymer product (in each reactor) may also be calculated using the terminal kinetic model and long chain approximations discussed above (see A. Hamielec, J. MacGregor, and A. Penlidis. Comprehensive Polymer Science and Supplements, volume 3, chapter Copolymerization, page 17, Elsevier, 1996).

For a given catalyst system, the comonomer (e.g. 1-octene) incorporation is a function of the monomer (e.g. ethylene) conversion, the comonomer to monomer ratio in the reactor (γ) and the reactivity ratio of monomer 1 (e.g. ethylene) over monomer 2 (e.g. 1-octene): r₁=k_(p11)/k_(p12).

For a CSTR, the molar ratio of ethylene to comonomer in the polymer (Y) can be estimated knowing the reactivity ratio r₁ of the catalyst system and knowing the ethylene conversion in the reactor (Q_(m1)). A quadratic equation can be derived using the May and Lewis equation for instantaneous comonomer incorporation (see “Copolymerization” by A. Hamielec, J. MacGregor, and A. Penlidis in Comprehensive Polymer Science and Supplements, volume 3, Chapter 2, page 17, Elsevier, 1996) and solving the mass balance around the reaction. The molar ratio of ethylene to 1-octene in the polymer is the negative root of the following quadratic equation:

$\begin{matrix} {{{{- Y^{2}}\frac{\gamma}{4}} + {\left\lbrack {r_{1} + {Q_{m1}\left( {1 - r_{1}} \right)} + \frac{\gamma}{4}} \right\rbrack Y} - Q_{m1}} = 0} & (9) \end{matrix}$

where Y is the molar ratio of ethylene to 1-octene in the polymer, γ is the mass flow ratio of 1-octene to ethylene going the reactor, r₁ is the reactivity ratio of monomer 1 to monomer 2 for the catalyst system (r₁=k_(p11)/k_(p12)) and Q_(m1) is the ethylene monomer fractional conversion.

The branching frequency can then be calculated knowing the molar ratio of monomer 1 to monomer 2 in the polymer:

$\begin{matrix} {{BF} = \frac{500}{Y + 1}} & (10) \end{matrix}$

where Y, is the molar ratio of monomer 1 (ethylene) over monomer 2 (1-octene) in the polymer, and BF is the branching frequency (branches per 1000 carbon atoms).

The overall branching frequency distribution (BFD) of the ethylene composition can be calculated by knowing the molecular weight distribution and weight fraction of polymer made in each reactor, and the average branching frequency (BF) of the ethylene copolymer made in each reactor. The fraction of polymer made in each reactor can be calculated from the experimental mass flows and conversion of monomer and comonomer in each reactor. The branching frequency distribution function is obtained by calculating the average branch content for each molecular weight value of the overall molecular weight distribution function made from the two Flory distributions:

$\begin{matrix} {{BF_{MW}} = \frac{{w_{R1}BF_{R1}{F_{1}\left( {MW_{R1}} \right)}} + {w_{R2}BF_{R2}{F_{2}\left( {MW_{R2}} \right)}}}{{w_{R1}{F_{1}\left( {MW_{R1}} \right)}} + {w_{R2}{F_{2}\left( {MW_{R2}} \right)}}}} & (11) \end{matrix}$

where BF_(MW) is the branching at molecular weight (MW), w_(R1) and w_(R2) are the weight fraction of polymer made in Reactor 1 and Reactor 2, BF_(R1) and BF_(R2) are the average branching frequency of polymer made in R1 and R2 (from Equations 9 and 10), F₁(MW_(R1)) and F₂(MW_(R2)) are Flory distribution function from Reactor 1 and Reactor 2. The overall branching frequency of the polyethylene composition is given by the weighted average of the branching frequency of the polymer made in each reactor:

BF _(avg) =w ₁ BF ₁ +w ₂ BF ₂  (12)

where, BF_(an)g is the average branching frequency for the total polymer (e.g. the polyethylene composition), w₁ and w₂ are the weight fraction of material made in each reactor, BF₁ and BF₂ are the branching frequency of material made in each reactor (e.g. the branching frequency of the first and second ethylene copolymers).

For the polymer obtained in each reactor, the key resin parameters which are obtained from the above described kinetic model are the molecular weights Mn, Mw and Mz, the molecular weight distributions M_(w)/M_(n) and Mz/Mw and the branching frequency (SCB/1000 Cs). With this information in hand, a component (or composition) density model and a component (or composition) melt index, I₂, model was used according to the following equations, which were empirically determined, to calculate the density and melt index I₂ of each of the first and second ethylene copolymers:

Density:

$\frac{1}{\rho} = {{{1.0}142} + {{0.0}033\left( {1{{.22} \cdot {BF}}} \right)^{0.8346}} + \frac{{0.0}30{3.k^{0.9804}}}{1 + \frac{0.3712}{e^{1.22BF}}}}$

where, BF is the branching frequency, k=Log₁₀ (M^(n)/1000)

Melt Index, I₂ (MI):

${Lo{g_{10}({MI})}} = {{{7.8}998} - {{3.9}089Lo{g_{10}\left( \frac{M_{w}}{1000} \right)}} - {{0.2}799\frac{M_{n}}{M_{w}}}}$

Hence, the above models were used to estimate the branch frequency, weight fraction (or weight percent), melt index and the density of the polyethylene composition components, which were formed in each of reactor 1 and 2 (i.e. the first and second ethylene copolymers).

TABLE 1 Reactor Conditions Example No. Inv. 1 Inv. 2 Inv. 3 Reactor 1 Ethylene (kg/h) 22.2 22.2 22.4 Octene (kg/h) 0.80 0.80 0.80 Hydrogen (g/h) 0.80 0.50 1.10 Solvent (kg/h) 187 187 187 Reactor feed inlet 35 35 35 temperature (° C.) Reactor 163 162.9 162.9 Temperature (° C.) Titanium Catalyst 0.0236 0.0247 0.0210 (ppm) Reactor 1 Ethylene 93.0 93.0 93.0 Conversion (%) Reactor 2 Ethylene (kg/h) 52 52 52 Octene (kg/h) 0 0 0 Hydrogen (g/h) 4 4 4 Solvent (kg/h) 287.9 287.9 287.9 Reactor feed inlet 35 35 35 temperature (° C.) Reactor 199.9 200 199.9 Temperature (° C.) Reactor Pressure 16.0 16.0 16.0 (MPa) Titanium Catalyst 0.0983 0.0987 0.0816 (ppm) Reactor 2 Ethylene 89.0 89.0 89.0 Conversion (%) Rate (kg/h) 71.0 71.0 70.9

TABLE 2 Resin Properties Example No. Inv. 1 Inv. 1* Inv. 2 Inv. 2* Inv. 3 Inv. 3* Nucleating Agent None HPN20E None HPN20E None HPN20E Density (g/cm³) 0.9539 0.9564 0.954 0.9569 0.9546 0.9574 Base Resin Density 0.9539 0.954 0.9546 (g/cm³) density increase after 0.0025 0.0029 0.0028 nucleation Melt Index I₂ (g/10 min), 20.4 13.5 29.1 base resin Melt Index I₆ (g/10 min) 75 53.1 103 Melt Index I₁₀ (g/10 min) 141 95 170 Melt Index I₂₁ (g/10 min) 400 312 524 Melt Flow Ratio (I₂₁/I₂) 19.6 23.1 18 Stress Exponent 1.19 1.25 1.15 Melt Flow Ratio (I₁₀/I₂) 7.73 7.08 6.08 Rheological Properties Shear viscosity (η) at 10⁵ 7.3 7.0 7.4 s⁻¹ (240° C., Pa-s) 100/η at 10⁵ s⁻¹ (240° C.), 13.7 14.3 13.5 Processability Indicator Shear viscosity Ratio 24.1 34.8 16.9 η₁₀₀/ η₁₀₀₀₀₀ (240° C.) Zero Shear Viscosity— 401.46 685.04 276.45 190° C. (Pa-s) DRI 0.15 0.243 0.119 G′@G″ = 500 Pa 12.8 20.7 9.2 DSC Primary Melting Peak 129.84 131.38 130.42 132.03 130.27 132.35 (° C.) Heat of Fusion (J/g) 218.1 221.1 215.5 247.5 217.2 228.2 Crystallinity (%) 75.2 76.23 74.31 85.34 74.89 78.7 Branch Frequency— FTIR (uncorrected for chain end —CH₃) Branch Freq 1.8 1.7 1.5 (SCB per 1000 Cs) Comonomer ID 1- 1- 1- octene octene octene Comonomer Content 0.4 0.3 0.3 (mole %) Comonomer Content 1.4 1.4 1.2 (wt %) Internal Unsat/100 C 0.017 0.018 0.017 Side Chain Unsat/100 C 0 0.001 0 Terminal Unsat/100 C 0.021 0.022 0.019 TREF High Elution Peak (° C.) 95.3 95.2 95.4 CDBI ₅₀ 82.1 83.8 82.3 Co/Ho 0.2 0.1 0.1 HD Fraction—Approx. 87.2 88.8 88.1 wt % GPC M_(n) 21653 24905 23930 M_(w) 49521 55953 46233 M_(z) 89061 109160 76726 Polydispersity Index 2.29 2.25 1.93 (M_(w)/M_(n)) Extractables & Regulatory Testing Hexane Extractables 0.19 0.15 0.14 (wt. %)—Plaque Example No. Comp. 4 Comp. 4* Comp. 5 Comp. 5* Nucleating Agent None HPN20E None HPN20E Density (g/cm³) 0.9555 0.9602 0.9591 0.9629 Base Resin Density (g/cm³) 0.9555 0.9591 density increase after 0.0047 0.0038 nucleation Melt Index I₂ (g/10 min), 19.1 30 base resin Melt Index I₆ (g/10 min) 66.1 106 Melt Index I₁₀ (g/10 min) 111 178 Melt Index I₂₁ (g/10 min) 311 530 Melt Flow Ratio (I₂₁/I₂) 16.2 17.7 Stress Exponent 1.13 1.15 Melt Flow Ratio (I₁₀/I₂) 6.08 6.09 Rheological Properties Shear viscosity (η) at 8.6 7.5 10⁵ s⁻¹ (240° C., Pa-s) 100/η at 10⁵ s⁻¹ (240° C.), 11.6 13.3 Processability Indicator Shear viscosity Ratio 22.1 16.1 η₁₀₀/η₁₀₀₀₀₀ (240° C.) Zero Shear Viscosity— 405.74 262.56 190° C. (Pa-s) DRI 0.058 0.104 G′@G″ = 500 Pa 7.4 8.89 DSC Primary Melting Peak (° C.) 131.88 134.71 132.19 132.74 Heat of Fusion (J/g) 220.1 219.9 222.7 240.9 Crystallinity (%) 75.89 75.83 76.8 83.08 Branch Frequency—FTIR NA NA NA NA (uncorrected for chain end —CH₃) Branch Freq (SCB per 1000 Cs) Comonomer ID Comonomer Content (mole %) Comonomer Content (wt %) Internal Unsat/100 C Side Chain Unsat/100 C Terminal Unsat/100 C TREF NA NA NA NA High Elution Peak (° C.) CDBI ₅₀ Co/Ho HD Fraction— Approx. wt % GPC M_(n) 26037 24448 M_(w) 49362 45413 M_(z) 75170 73402 Polydispersity Index 1.9 1.86 (M_(w)/M_(n)) Extractables & Regulatory Testing Hexane Extractables 0.07 0.24 (wt. %)—Plaque Example No. Comp. 6 Comp. 6* Comp. 7 Comp. 8 Nucleating Agent None HPN20E Density (g/cm³) 0.9589 0.9628 0.966 0.968 Base Resin Density (g/cm³) 0.9589 density increase after 0.0039 nucleation Melt Index I₂ (g/10 min), 19.7 1.2 6 base resin Melt Index I₆ (g/10 min) 72.9 5.49 24.5 Melt Index I₁₀ (g/10 min) 126 11 45.5 Melt Index I₂₁ (g/10 min) 394 69 194 Melt Flow Ratio (I₂₁/I₂) 19.7 57 33 Stress Exponent 1.19 1.38 1.27 Melt Flow Ratio (I₁₀/I₂) 6.55 9.4 7.59 Rheological Properties Shear viscosity (η) at 7.5 5.4 5.2 10⁵ s⁻¹ (240° C., Pa-s) 100/η at 10⁵ s⁻¹ (240° C.), 13.3 18.5 19.2 Processability Indicator Shear viscosity Ratio 24.2 185 87 η₁₀₀/ η₁₀₀₀₀₀ (240° C.) Zero Shear Viscosity— 422.42 190° C. (Pa-s) DRI 0.152 G′@G″ = 500 Pa 15.5 DSC Primary Melting Peak (° C.) 132.16 133.74 133.80 Heat of Fusion (J/g) 222.8 244.74 244.80 Crystallinity (%) 76.82 84.39 84.41 Branch Frequency—FTIR NA NA NA NA Branch Freq/1000 C Comonomer ID Comonomer Content (mole %) Comonomer Content (wt %) Internal Unsat/100 C Side Chain Unsat/100 C Terminal Unsat/100 C TREF NA NA NA NA High Elution Peak (° C.) CDBI ₅₀ Co/Ho HD Fraction—Approx. wt % GPC M_(n) 25786 12764 14377 M_(w) 50786 96923 69182 M_(z) 89336 280629 163561 Polydispersity Index 1.97 7.59 4.81 (M_(w)/M_(n)) Hexane Extractables (%)— 0.18 0.21 0.53 Plaque

TABLE 3 Polyethylene Composition Component Properties Example No. Inv. 1 Inv. 2 Inv. 3 Density (g/cm³) 0.9539 0.954 0.9546 I₂ (g/10 min.) 20.4 13.5 29.1 Stress Exponent 1.19 1.25 1.15 MFR (I₂₁/I₂) 19.6 23.1 18 Mw/Mn 2.29 2.25 1.93 First Ethylene Copolymer Weight fraction 0.3066 0.3069 0.3063 Mw 92001 117778 74433 I₂ (g/10 min.) 1.22 0.46 2.79 SCB1/1000 C. 0.625 0.633 0.617 Density, d1 (g/cm³) 0.9441 0.9417 0.9463 Second Ethylene Copolymer Weight fraction 0.6934 0.6931 0.6937 Mw 37539 37851 37179 I₂ (g/10 min.) 40.3 39.0 41.9 SCB2/1000 C. 0.2 0.2 0.2 Density, d2 (g/cm³) 0.957 0.957 0.9571 SCB1/SCB2 3.13 3.17 3.09 Estimated (d2 − d1), 0.0129 0.0153 0.0108 g/cm³ Example No. Comp. 4 Comp. 5 Comp. 6 Comp. 7 Comp. 8 Density (g/cm³) 0.9555 0.9591 0.9589 0.966 0.968 I₂ (g/10 min.) 19.1 30 19.7 1.2 6 Stress Exponent 1.13 1.15 1.19 1.38 1.27 MFR (I₂₁/I₂) 16.2 17.7 19.7 57 33 Mw/Mn 1.9 1.86 1.97 7.59 4.81 First Ethylene Homopolymer Weight fraction 0.306 0.3054 0.306 0.47 0.515 Mw 67921 74784 92709 177980 115059 I₂ (g/10 min.) 3.98 2.73 1.18 0.09 0.51 SCB1/1000 C. 0 0 0 0 0 Density, d1 (g/cm³) 0.9545 0.9537 0.9519 0.9464 0.95 Second Ethylene Homopolymer Weight fraction 0.694 0.6946 0.694 0.53 0.485 Mw 5029 37695 38241 13394 13105 I₂ (g/10 min.) 13.0 39.7 37.5 2264.0 2465.0 SCB2/1000 C. 0 0 0 0 0 Density, d2 (g/cm³) 0.9570 0.9595 0.9594 0.9685 0.9687 SCB1/SCB2 NA NA NA NA NA Estimated (d2 − d1), 0.0025 0.0058 0.0075 0.0221 0.0187 g/cm³

TABLE 4 Plaque Properties Example No. Inv. 1 Inv. 1* Inv. 2 Inv. 2* Inv. 3 Inv. 3* Tensile Properties (Plaques) Elong. at Yield (%) 10 9 10 9 10 9 Elong. at Yield Dev. (%) 0.1 0.3 0.1 0.1 0.1 0.3 Yield Strength (MPa) 28.8 29.9 28.5 30.9 29.6 30.4 Yield Strength Dev. (MPa) 0.3 0.6 0.2 0.2 0.2 0.2 Ultimate Elong. (%) 213 652 535 1377 118 775 Ultimate Elong.Dev. (%) 159 672 412 70 87 656 Ultimate Strength (MPa) 18.9 13.9 15.7 19.9 19.3 14.2 Ultimate Strength Dev. (MPa) 7.2 3 1 2.1 8.1 1.3 Sec Mod 1% (MPa) 1226.8 1296 1219 1418 1266 1371 Sec Mod 1% (MPa) Dev. 56 122 39 17 54 33 Sec Mod 2% (MPa) 959 1002 944 1071 990 1045 Sec Mod 2% (MPa) Dev. 26 59 16 6 20 6 Youngs Modulus (MPa) 1594.6 1633.1 313.3 Youngs Modulus (MPa) Dev. Flexural Properties (Plaques) Flex Secant Mod. 1% (MPa) 1262 1369 1250 1455 1259 1258 Flex Sec Mod 1% (MPa) Dev. 30 30 16 44 39 22 Flex Secant Mod. 2% (MPa) 1063 1143 1060 1214 1065 1051 Flex Sec Mod 2% (MPa) Dev. 26 9 12 35 35 20 Flex Tangent Mod. (MPa) 1493 1664 1456 1747 1471 1531 Flex Tangent Mod. Dev. 65 153 52 32 86 39 (MPa) Flexural Strength (MPa) 38 38.8 37.8 42.2 38.1 35.9 Flexural Strength Dev. (MPa) 0.6 0.3 0.3 0.3 0.9 0.6 Impact Properties (Plaques) Izod Impact (ft-lb/in) 0.8 0.9 0.8 Environmental Stress Crack Resistance ESCR Cond. B at 100% CO— 1 2 0 630 (hrs) Miscellaneous VICAT Soft. Pt. (° C.)—Plaque 127.5 127 127.6 Heat Deflection Temp. (° C.) 78.3 79.3 79.9 @66 PSI Example No. Com. 4 Com. 4* Com. 5 Com. 5* Tensile Properties (Plaques) Elong. at Yield (%) 10 8 9 9 Elong. at Yield Dev. (%) 0.1 0.2 0.1 0.1 Yield Strength (MPa) 30.3 32.8 30.9 32.2 Yield Strength Dev. (MPa) 0.2 0.2 0.3 0.1 Ultimate Elong. (%) 99 153 26 132 Ultimate Elong. Dev. (%) 85 134 16 119 Ultimate Strength (MPa) 20 19.3 27.7 13.3 Ultimate Strength Dev. (MPa) 8 7.7 1.3 0.6 Sec Mod 1% (MPa) 1308 1646 1421 1574 Sec Mod 1% (MPa) Dev. 73 19 43 23 Sec Mod 2% (MPa) 1018 1194 1073 1151 Sec Mod 2% (MPa) Dev. 25 8 23 8 Youngs Modulus (MPa) 2001.1 2141.4 Youngs Modulus (MPa) Dev. 414.9 391.8 Flexural Properties (Plaques) Flex Secant Mod. 1% (MPa) 1369 1572 1514 1335 Flex Sec Mod 1% (MPa) Dev. 34 46 30 41 Flex Secant Mod. 2% (MPa) 1156 1311 1268 1105 Flex Sec Mod 2% (MPa) Dev. 30 32 28 31 Flex Tangent Mod. (MPa) 1590 1902 1733 1619 Flex Tangent Mod. Dev. (MPa) 47 62 43 79 Flexural Strength (MPa) 40.1 44 43.3 37 Flexural Strength Dev. (MPa) 0.7 1 0.5 1.2 Impact Properties (Plaques) Izod Impact (ft-lb/in) 0.8 0.6 0.6 Environmental Stress Crack Resistance ESC Cond. B at 100% <15 <15 <15 CO630 (hrs) Miscellaneous VICAT Soft. Pt. (° C.)—Plaque 128.5 128.8 128.8 Heat Deflection Temp. (° C.) 83.2 86.3 86.3 @66 PSI Example No. Com. 6 Com. 6* Comp. 7 Comp. 8 Tensile Properties (Plaques) Elong. at Yield (%) 10 8 7 Elong. at Yield Dev. (%) 0.1 0.2 0 Yield Strength (MPa) 30.9 33.5 34.2 Yield Strength Dev. (MPa) 0.2 0.1 0.4 Ultimate Elong. (%) 200 133.6 7 Ultimate Elong. Dev. (%) 76 91.6 0 Ultimate Strength (MPa) 13.3 15.2 34.2 Ultimate Strength Dev. (MPa) 0.6 0.6 0.4 Sec Mod 1% (MPa) 1381 1603 1792 1996 Sec Mod 1% (MPa) Dev. 65 39 165 109 Sec Mod 2% (MPa) 1051 1198 1233 1365 Sec Mod 2% (MPa) Dev. 25 15 33 29 Youngs Modulus (MPa) 2220.1 Youngs Modulus (MPa) Dev. 295 Flexural Properties (Plaques) Flex Secant Mod. 1% (MPa) 1454 1692 1856 1940 Flex Sec Mod 1% (MPa) Dev. 51 99 79 57 Flex Secant Mod. 2% (MPa) 1218 1411 1553 1580 Flex Sec Mod 2% (MPa) Dev. 45 83 29 40 Flex Tangent Mod. (MPa) 1692 2023 2167 2309 Flex Tangent Mod. Dev. (MPa) 42 49 191 147 Flexural Strength (MPa) 41.7 47.7 48.5 49.1 Flexural Strength Dev. (MPa) 1.1 1.9 0.4 1.3 Impact Properties (Plaques) Izod Impact (ft-lb/in) 0.7 2 1.4 Environmental Stress Crack Resistance ESCR Cond. B at 100% CO— <15 <16 4 630 (hrs) Miscellaneous VICAT Soft. Pt. (° C.)—Plaque 128.7 128.4 127.4 Heat Deflection Temp. (° C.) 84.6 77.2 76.2 @66 PSI

Method of Making Compression Molded Film

A laboratory scale compression molding press Wabash G304 from Wabash MPI was used to prepare compression molded film from the inventive and comparative polyethylene compositions. A metal frame of required dimensions and thickness was filled with a measured quantity of resin (e.g. pellets of a polyethylene composition) and sandwiched between two polished metal plates. The measured polymer quantity used was sufficient to obtain the desired film thickness. Polyester sheets (Mylar) were used on top of the metal backing plates to prevent the sticking of the resin to the metal plates. This assembly with the resin was loaded in the compression press and preheated at 200° C. under a low pressure (e.g. 2 tons or 4400 lbs per square foot) for five minutes. The platens were closed and a high pressure (e.g., 28 tons or 61670 lbs per square foot) was applied for another five minutes. After that, the press was cooled to about 45° C. at a rate of about 15° C. per minute. On completion of the cycle, the frame assembly was taken out, disassembled and the film (or plaque) was separated from the frame. Subsequent tests were done after at least 48 hours after the time at which the compression molding was carried out.

Determination of the Oxygen Transmission Rate (OTR) of a Compression Molded Film Using a Masking Method

The oxygen transmission rate (OTR) of the compression-molded film was tested using an OX-TRAN® 2/20 instrument manufactured by MOCON Inc, Minneapolis, Minn., USA using a version of ASTM F1249-90. The instrument had two test cells (A and B) and each film sample was analyzed in duplicate. The OTR result reported was the average of the results from these two test cells (A and B). The test was carried out at a temperature of 23° C. and at a relative humidity of 0%. Typically, the film sample area used for OTR testing was 100 cm². However, for barrier testing of films where there is a limited amount of sample, an aluminum foil mask was used to reduce the testing area. When using the mask, the testing area was reduced to 5 cm². The foil mask had adhesive on one side to which the sample was attached. A second foil was then attached to the first to ensure a leak free seal. The carrier gas used was 2% hydrogen gas in a balance of nitrogen gas and the test gas was ultra high purity oxygen. The OTR of the compression molded films were tested at the corresponding film thickness as obtained from the compression molding process. However, in order to compare different samples, the resulting OTR values have been normalized to a film thickness value of 1 mil.

Determination of the Water Vapor Transmission Rate (WVTR) of a Compression Molded Film Using a Masking Method

The water vapor transmission rate (WVTR) of the compression-molded film was tested using a PERMATRAN-W® 3/34 instrument manufactured by MOCON Inc, Minneapolis, Minn., USA using a version of ASTM D3985. The instrument had two test cells (A and B) and each film sample was analyzed in duplicate. The WVTR result reported was the average of the results from these two test cells (A and B). The test is carried out at a temperature of 37.8° C. and at a relative humidity of 100%. Typically, the film sample area used for WVTR testing was 50 cm². However, for barrier testing of films where there was a limited amount of sample, an aluminum foil mask was used to reduce the testing area. When using the mask, the testing area was reduced to 5 cm². The foil mask has adhesive on one side to which the sample was attached. A second foil was then attached to the first to ensure a leak free seal. The carrier gas used was ultra high purity nitrogen gas and the test gas was water vapor at 100% relative humidity. The WVTR of the compression molded films was tested at the corresponding film thickness as obtained from the compression molding process. However, in order to compare different samples, the resulting WVTR values have been normalized to a film thickness value of 1 mil.

The barrier properties (OTR and WVTR) of pressed films made from comparative and inventive polyethylene compositions are provided in Table 5.

TABLE 5 OTR and WVTR Properties of Compression Molded Films Example No. Inv. 1 Inv. 1* Inv. 2 Inv. 2* Inv. 3 Inv. 3* WVTR—thickness (mil) 2.9 2.4 1.7 2.1 2.85 1.85 WVTR g/100 IN²/Day 0.1279 0.0949 0.1706 0.0965 0.0822 0.1109 (relative humidity = 100%, 37.8° C., atm) WVTR in g/100 0.3709 0.2278 0.2900 0.2027 0.2343 0.2052 IN²/Day—normalized thickness (1 mil) Improvement in WVTR  38.59%  30.13%  12.42% property after nucleation OTR—thickness (mil) 2.9 2.4 1.7 2.1 2.85 1.85 OTR in cm³/100 in²/day 54.23 31.22 99.21 40.16 47.61 49.79 (relative humidity = 0%, 23° C., atm) OTR in cm³/100 157.2670 74.93 168.6570 84.34 135.6885 92.11 IN²/Day—normalized thickness (1 mil) Improvement in OTR 52.4% 50.0% 32.1% property after nucleation Example No. Comp. 4 Comp. 4* Comp. 5 Comp. 5* WVTR—thickness (mil) 1.75 2.5 2.45 2.1 WVTR g/100 IN²/Day (relative 0.1765 0.0819 0.0966 0.0586 humidity = 100%, 37.8° C., atm) WVTR in g/100 IN²/Day— 0.3089 0.2048 0.2367 0.1231 normalized thickness (1 mil) Improvement in WVTR property 33.7% 48%   after nucleation OTR—thickness (mil) 1.75 2.5 2.45 2.1 OTR in cm³/100 IN²/Day 91.08 27.81 61.94 27.37 (relative humidity = 0%, 23° C., atm) OTR in cm³/100 IN²/Day— 159.3900 69.53 151.75 57.48 normalized thickness (1 mil) Improvement in OTR property 56.4% 62.1% after nucleation Example No. Comp. 6 Comp. 6* Comp. 7 Comp. 8 WVTR—thickness (mil) 2.5 2 2.7 2.4 WVTR g/100 IN²/Day (relative 0.1235 0.1053 0.0478 0.0617 humidity = 100%, 37.8° C., atm) WVTR in g/100 IN²/Day— 0.3088 0.2106 0.1291 0.1481 normalized thickness (1 mil) Improvement in WVTR property 31.8% after nucleation OTR—thickness (mil) 2.5 2 2.7 2.4 OTR in cm³/100 IN²/Day 56.2 41 21.14 28.45 (relative humidity = 0%, 23° C., atm) OTR in cm³/100 IN²/Day— 140.50 82.00 57.08 68.28 normalized thickness (1 mil) Improvement in OTR property 41.6% after nucleation

As can been seen from the data in Table 5, as well as FIGS. 2 and 3, the films made from the nucleated inventive polyethylene copolymer compositions had OTR and WVTR values which were comparable to the OTR and WVTR values of films made from the comparative polyethylene homopolymer compositions when similarly nucleated, even though the inventive compositions had lower densities.

Method of Making a Closure by Injection Molding

Nucleated versions of the Inventive polyethylene copolymer compositions as well as the comparative resins were made into closures using an injection molding process. A Sumitomo injection molding machine and 2.15-gram PCO (plastic closure only) 1881 carbonated soft drink (CSD) closure mold was used to prepare the closures herein. A Sumitomo injection molding machine (model SE75EV C250M) having a 28 mm screw diameter was used. The 4-cavity CSD closure mold was manufactured by Z-moulds (Austria). The 2.15-gram PCO 1881 CSD closure design was developed by Universal Closures Ltd. (United Kingdom). During the closure manufacturing, four closure parameters, the diameter of the top of the cap, the bore seal diameter, the tamper band diameter and the overall cap height, were measured and ensured to be within quality-control specifications.

An International Society of Beverage Technologists (ISBT) voluntary standard test method was used to determine the closure dimensions. The test used involves the selection of a mold cavity and the measurements on at least 5 closures made from that particular cavity. At least 14 dimensional measurements were obtained from closures that were aged for at least 1 week from the date of production. The closure dimension measurements were performed using a Vision Engineering, Swift Duo dual optical and video measuring system. All measurements were taken using Ox magnification and utilizing METLOGIX® M video measuring system software (see METLOGIX M³: Digital Comparator Field of View Software, User's Guide).

The closures were formed by injection molding, and the injection-molding processing conditions are given in Table 6.

TABLE 6 Injection Molding Processing Conditions Inv. Inv. Inv. Comp. Comp. Comp. Comp. Comp. Example No. 1* 2* 3* 4* 5* 6* 7 8 Closure No. 1 2 3 4 5 6 7 8 Additives (Color & Natural Natural Natural Natural Natural Natural Red Red Formulation) Part Weight (g) 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 Injection Speed 45 45 45 45 45 45 125 125 (mm/s) Cycle time (s) 4.41 4.36 4.35 4.36 4.35 4.36 4.12 3.65 Filling time (s) 0.684 0.651 0.640 0.651 0.640 0.639 0.245 0.245 Dosing time (s) 1.680 1.706 1.64 1.63 1.66 1.66 1.99 1.82 Minimum Cushion 9.79 9.756 9.76 9.75 9.76 9.76 9.93 9.93 (mm) Filling peak 10043 10132 8433 10123 8237 9164 13829 14309 pressure (psi) Full peak pressure 10101 10151 8447 10141 8247 9176 13829 14309 (psi) Hold end position 15.00 12.63 12.77 12.98 12.98 12.72 11.65 11.44 (mm) Clamp force (ton) 19 20 20 20 20 20 19.78 19.70 Fill start position 40.51 39.00 38.51 39 38.51 38.51 40.43 40.43 (mm) Dosing back 841 842 840 847 842 844 822 833 pressure (psi) Pack pressure (psi) 10067 10140 8434 10131 8236 9160 13752 14222 Filling time 1 (s) 0.688 0.648 0.640 0.648 0.640 0.640 0.248 0.248 Temperature 180 180 180 180 180 180 210 180 zone 1 (° C.) Temperature 185 185 185 185 185 185 215 185 zone 2 (° C.) Temperature 190 190 190 190 190 190 220 190 zone 3 (° C.) Temperature 200 200 200 200 200 200 230 200 zone 4 (° C.) Temperature 200 200 200 200 200 200 230 200 zone 5 (° C.) Mold temperature 10 10 10 10 10 10 10 10 stationary (° C.)

Oxygen Transmission Rate (OTR) of an Injection Molded Closure

To measure the oxygen transmission rate through a closure, ASTM D3985 (Standard Test Method for Oxygen Gas Transmission Rate Through Plastic Film and Sheeting Using a Coulometric Sensor) was adapted as follows.

First the closure's tamper evident band was removed. Next, the bottom edge of the closure was lightly roughed with sandpaper (for better adhesion to the epoxy) and then the closure was epoxied (using DEVCON® 2 part epoxy) to a testing plate so as to cover an outlet tube (for sweep gas) and inlet tube for N₂ introduction. The epoxy was allowed to dry overnight. One of the two gas tubes protruding into the closure interior carried inlet nitrogen gas flowing into the closure interior (nitrogen feed line), while the other one carried sweep gas (e.g. nitrogen plus permeates from the atmosphere surrounding the closure) out of the closure interior and into a detector. If any oxygen present in the atmosphere was permeating the closure walls it was detected as a component within the N₂ exiting the closure interior as sweep gas. The plate/closure/tubing apparatus was connected to an OX-TRAN low range instrument (PERMATRAN-C® Model 2/21 MD) with the testing plate placed in an environmental chamber controlled at a temperature of 23° C. A baseline measurement for the detection of atmospheric oxygen was also taken by using an impermeable aluminum foil (in parallel with the closure) for a side by side comparison of permeability. The oxygen permeability of the closure is reported as the average oxygen transmission rate in units of cm³/closure/day.

The oxygen barrier properties of injected molded closures made from comparative and inventive polyethylene compositions, all of which have been nucleated are provided in Table 7.

TABLE 7 OTR Average Example Closure (cm³/closure/ No. No. day) Test Gas Inv. 1* 1 0.0026 ambient air (20.9% oxygen) Inv. 2* 2 0.0024 ambient air (20.9% oxygen) Inv. 3* 3 0.0025 ambient air (20.9% oxygen) Comp. 4* 4 0.0024 ambient air (20.9% oxygen) Comp. 5* 6 0.0021 ambient air (20.9% oxygen) Comp. 6* 5 0.0016 ambient air (20.9% oxygen) Comp. 7 7 0.0012 ambient air (20.9% oxygen) Comp. 8 8 0.0017 ambient air (20.9% oxygen)

As can been seen from the data in Table 7, as well as FIG. 4, the closures made from the nucleated inventive polyethylene copolymer compositions had OTR values which were higher, but still comparable to the OTR values of closures made from the comparative polyethylene homopolymer compositions which are similarly nucleated, even though the inventive compositions are of lower density, sometimes much lower density.

The use of a lower density polyethylene copolymer composition as described by the present disclosure, may have advantages in the manufacture of articles which may benefit from good barrier properties, such as for example a cap or closure for a bottle, container or the like, or a fitment for a pouch or the like.

INDUSTRIAL APPLICABILITY

Polyethylene compositions exhibiting good barrier properties are disclosed. The polyethylene compositions may be useful in the preparation of, for example, closures for bottles or cast film. 

1. A polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂₁, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂₁/I₂, of less than 40; and a stress exponent of less than 1.40.
 2. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a melt index I₂, of from 5.0 to 40.0 g/10 min.
 3. The polyethylene copolymer composition of claim 1 wherein the density of the second ethylene copolymer is less than 0.020 g/cm³ higher than the density of the first ethylene copolymer.
 4. The polyethylene copolymer composition of claim 1 wherein the first ethylene copolymer has a melt index I₂ ¹, of from 0.1 to 5.0 g/10 min.
 5. The polyethylene copolymer composition of claim 1 wherein the second ethylene copolymer has a melt index I₂ ², of from 10 to less than 50 g/10 min.
 6. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a high load melt index I₂₁, of from 250 to 750 g/10 min.
 7. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a unimodal molecular weight distribution as determined by gel permeation chromatography.
 8. The polyethylene copolymer composition of claim 1 wherein the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is at least 2.5.
 9. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 4.0.
 10. The polyethylene copolymer composition of claim 1 wherein the first ethylene copolymer has a density of from 0.936 to 0.952 g/cm³.
 11. The polyethylene copolymer composition of claim 1 wherein the second ethylene copolymer has a density of less than 0.963 g/cm³.
 12. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a density of from 0.951 to 0.960 g/cm³.
 13. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has no long chain branching.
 14. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition has a composition distribution breadth index CDBI(50) of greater than 65 Wt %.
 15. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition comprises: from 20 to 55 wt % of the first ethylene copolymer; and from 80 to 45 wt % of the second ethylene copolymer.
 16. The polyethylene copolymer composition of claim 1 wherein the first and second ethylene copolymers are copolymers of ethylene and 1-octene.
 17. The polyethylene copolymer composition of claim 1 wherein the polyethylene composition further comprises a nucleating agent.
 18. The polyethylene copolymer composition of claim 17 wherein the nucleating agent is a salt of a dicarboxylic acid compound.
 19. The polyethylene copolymer composition of claim 18 wherein the polyethylene composition comprises from 20 to 4000 ppm of the nucleating agent based on the combined weight of the first ethylene copolymer and the second ethylene copolymer.
 20. An injection molded article comprising the polyethylene copolymer composition of claim
 1. 21. A compression molded article comprising the polyethylene copolymer composition of claim
 1. 22. A closure comprising the polyethylene copolymer composition of claim
 1. 23. A film comprising the polyethylene copolymer composition of claim
 1. 24. A cast film comprising the polyethylene copolymer composition of claim
 1. 25. The polyethylene copolymer composition of claim 1, wherein the polyethylene copolymer composition is made by a process comprising contacting at least one single site polymerization catalyst system with ethylene under solution polymerization conditions in at least two polymerization reactors.
 26. A process to prepare a polyethylene copolymer composition, the polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of from less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂₁, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂₁/I₂, of less than 40; and a stress exponent of less than 1.40; wherein the process comprises contacting at least one single site polymerization catalyst system with ethylene and at least one alpha-olefin under solution polymerization conditions in at least two polymerization reactors.
 27. The process of claim 26 wherein the at least two polymerization reactors comprise a first reactor and a second reactor configured in series.
 28. A polymer composition comprising from 1 to 100 percent by weight of a polyethylene copolymer composition, the polyethylene copolymer composition comprising: (1) 10 to 70 wt % of a first ethylene copolymer having a melt index I₂ ¹, of from 0.1 to 10 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960 g/cm³; and (2) 90 to 30 wt % of a second ethylene copolymer having a melt index I₂ ², of less than 50 g/10 min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; and a density higher than the density of the first ethylene copolymer, but less than 0.970 g/cm³; wherein the density of the second ethylene copolymer is less than 0.031 g/cm³ higher than the density of the first ethylene copolymer; the melt index, I₂ ¹ of the first ethylene copolymer is less than the melt index, I₂ ² of second ethylene copolymer; the ratio (SCB1/SCB2) of the number of short chain branches per thousand carbon atoms in the first ethylene copolymer (SCB1) to the number of short chain branches per thousand carbon atoms in the second ethylene copolymer (SCB2) is greater than 2.0; and wherein the polyethylene copolymer composition has a molecular weight distribution M_(w)/M_(n), of from 1.8 to 7.0; a density of at least 0.949 g/cm³; a high load melt index I₂₁, of at least 200 g/10 min; a Z-average molecular weight M_(Z), of less than 200,000; a melt flow ratio I₂₁/I₂, of less than 40; and a stress exponent of less than 1.40.
 29. The polymer composition of claim 28 wherein the polyethylene copolymer composition further comprises a nucleating agent.
 30. The polymer composition of claim 29 wherein the wherein the nucleating agent is a salt of a dicarboxylic acid compound.
 31. The polymer composition of claim 30 wherein the polyethylene copolymer composition comprises from 20 to 4000 ppm of the nucleating agent based on the combined weight of the first ethylene copolymer and the second ethylene copolymer.
 32. The polyethylene copolymer composition of claim 17, which when made into a PCO 1881 CSD closure, has an OTR of less than 0.0030 cm³/closure/day.
 33. A film comprising the polyethylene copolymer composition of claim 17 and having a normalized OTR of ≤100 cm³/100 in²/day.
 34. A film comprising the polyethylene copolymer composition of claim 17 and having a normalized WVTR of ≤0.250 g/100 in²/day. 